Bioplastics &#038; Recycled Plastics: How Sustainable Materials Are Reshaping Footwear

Excellence and innovation have always been at the heart of everything we do. In today’s global context, we firmly believe

2024 “Digital and Ecological Transition” Grant from the Chamber of Commerce of Marche

With the support of the “Digital and Ecological Transition” grant, promoted by the Chamber of Commerce of Marche, we carried

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Pu.Ro. Joins ZDHC’s Roadmap to Zero: A Strategic Commitment to Sustainable Chemical Management

Excellence and innovation have always been at the heart of everything we do. In today’s global context, we firmly believe that excellence must go hand in hand with sustainability. Environmental responsibility is no longer optional: it is a corporate imperative.

Joining the ZDHC Roadmap to Zero initiative marks an important milestone in our ongoing commitment to environmental responsibility and sustainable practices.

What is ZDHC and Why Does It Matter?

The ZDHC (Zero Discharge of Hazardous Chemicals) programme is a global initiative that brings together stakeholders from across the fashion and footwear value chain – brands, chemical formulator and supplier – with a shared goal: to eliminate hazardous chemicals from industrial processes.

Through harmonized guidelines, practical tools and dedicated training, ZDHC promotes best practices in chemical safety, transparency and traceability. Becoming a member means embracing not only operational changes, but also a cultural shift to protect the environment, workers’ health and consumers.

A Choice Aligned with Our Core Values

We operate in the footwear industry with the goal of combining quality, innovation and responsibility. Adopting the ZDHC framework is a natural step on our path to reducing environmental impact and building a more sustainable supply chain.

Our decision to join the ZDHC Roadmap to Zero reflects our core values:

✅ Environmental responsibility
✅ Commitment to chemical safety
✅ Collaboration with a global network of forward-thinking partners
✅ Transparency in manufacturing processes

Our Commitments as ZDHC Contributors

By joining the ZDHC programme, we pledge to:

✅ Reduce the environmental impact of our production by using chemicals in compliance with the ZDHC Manufacturing Restricted Substances List (MRSL)
✅ Enhance the safety and traceability of the chemicals we use
✅ Support a broader cultural shift within the footwear industry
✅ Provide our customers more sustainable products

Leading the Change Towards a Zero-Impact Future

The footwear industry is undergoing a great transformation. Consumers are demanding greater transparency, regulations are tightening and businesses are being called upon to take real responsibility.

With this decision, we’re not just keeping pace with change. We’re striving to lead it. We are committed to taking proactive, measurable and collective action.

We recognize that the road ahead is complex, but it’s also essential. Our participation in the ZDHC Roadmap to Zero is just the beginning. Every day, we will continue working to reduce our impact and to help make footwear manufacturing safer, cleaner and more sustainable.

In the months ahead, we’ll keep our stakeholders and customers informed of our progress. We firmly believe that the future of our industry depends on transparency, collaboration, and a shared commitment to protecting the planet.

Follow us as we continue this journey, sharing milestones, new goals, and real impact. Together, we can create a cleaner, smarter, and more sustainable footwear industry.

28/07/2025

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Bioplastics & Recycled Plastics: How Sustainable Materials Are Reshaping Footwear

They are revolutionizing footwear sole production, offering sustainable solutions without compromising quality or performance. From bio-based TPU to recycled EVA,

2024 “Digital and Ecological Transition” Grant from the Chamber of Commerce of Marche

With the support of the “Digital and Ecological Transition” grant, promoted by the Chamber of Commerce of Marche, we carried

Send us a message

2024 “Digital and Ecological Transition” Grant from the Chamber of Commerce of Marche

With the support of the “Digital and Ecological Transition” grant, promoted by the Chamber of Commerce of Marche, we carried out a comprehensive energy audit and implemented a consumption monitoring system to enhance the efficiency of our production processes.

28/07/2025

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Bioplastics & Recycled Plastics: How Sustainable Materials Are Reshaping Footwear

They are revolutionizing footwear sole production, offering sustainable solutions without compromising quality or performance. From bio-based TPU to recycled EVA,

Pu.Ro. Joins ZDHC’s Roadmap to Zero: A Strategic Commitment to Sustainable Chemical Management

Excellence and innovation have always been at the heart of everything we do. In today’s global context, we firmly believe

Send us a message

Bioplastics and recycled plastics. A more sustainable future for shoe sole molding.

From raw materials to recycling: how bioplastics and recycled plastics are revolutionizing sole molding for a greener future.

In recent years, the footwear industry and the fashion industry as a whole have seen a growing interest in innovative and sustainable materials, as well as the recycling of end-of-life shoes, with the goal of creating increasingly green footwear. This trend stems from the need to reduce the environmental impact of industrial production and meet the demands of an increasingly sustainability-conscious consumer base. But what exactly are bioplastics, and how can they be used in shoe sole molding?

What are bioplastics?

Bioplastics are polymeric materials that can be renewable, biodegradable, or both. They are divided into two main categories:

Renewable bioplastics: derived from plant biomass such as corn starch, sugar cane, cellulose, or vegetable oils. They may have similar characteristics to traditional plastics without necessarily being biodegradable.

Biodegradable bioplastics: they degrade naturally thanks to the action of microorganisms present in the environment. Among the best-known examples are PLA (polylactic acid), PBAT (polybutylene adipate-co-terephthalate), and PHA (polyhydroxyalkanoates).

Bioplastic vs. Recycled Plastic: What’s the Difference?

The terms bioplastic and recycled plastic are often confused. However, there are substantial differences:

Bioplastic: A material produced from renewable sources or with biodegradable capabilities. It is not necessarily derived from pre-existing plastic, but rather from plant biomass or innovative biochemical processes.
Recycled plastic: A traditional plastic (of fossil origin) recovered from post-industrial or post-consumer waste and subjected to a mechanical or chemical recycling process for reuse in new products.
Both solutions contribute to environmental sustainability, but in different ways: bioplastics reduce dependence on fossil fuels, while recycled plastic minimizes waste and extends the material’s life cycle.

New materials for molding shoe soles

The use of biopolymers and secondary raw materials in the footwear industry is becoming an increasingly widespread option, representing an ecological breakthrough that meets sustainability demands without compromising quality and performance. Injecting these materials into molding presses allows for the creation of soles with characteristics similar to conventional plastics, but with a lower environmental impact. Bioplastics can also be modified to achieve different hardnesses, colors, and textures, meeting the needs of luxury and fashion brands. Some innovative solutions include:

Biobased TPU: Thermoplastic polyurethane is a widely used material for molding shoe soles due to its high abrasion resistance, elasticity, and lightness. Biobased versions, derived from vegetable oils such as soybean or castor, offer the same performance while reducing the use of fossil-based materials.
Recycled TPU: An increasingly popular sustainable alternative is recycled TPU, obtained by granulating industrial waste. This material maintains the same mechanical properties as virgin TPU and contributes to a more circular production model.
Biobased or recyclable polyurethanes: Used for the production of lightweight and comfortable soles, especially in high-end and athletic footwear. They can be formulated with biobased components or designed for easy recycling.
Biobased EVA: Ethylene Vinyl Acetate is a material known for its lightness and shock absorption. Formulations containing a percentage of biobased EVA, derived from sugarcane, reduce the use of fossil-based polymers without compromising the sole’s flexibility and durability.
Natural and recycled rubber: Used to produce various footwear styles, including elegant ones, it can be blended with recycled materials to improve sustainability.

Towards a more sustainable future for the footwear sector

Sustainability has become a key factor for the footwear industry in today’s market, as highlighted by the 21st International Conference of the UITIC (International Union of Footwear Industry Technicians), which in 2023 addressed the theme “Towards Sustainability Through Innovation.” More and more brands and manufacturers are rethinking their production processes to reduce energy consumption, use secondary or biobased raw materials, and monitor greenhouse gas emissions.

With the growing demand for eco-friendly materials from fashion brands and consumers, the adoption of biopolymers or recycled plastics, as well as innovative and eco-friendly fabrics for uppers, is becoming increasingly widespread, contributing to a greener future for the fashion industry.

Our commitment to sustainable innovation

We also believe that the future of the footwear industry is green. We use biobased or recycled TPU certified by the Global Recycle Standard (GRS) and recover our industrial waste through the in-house granulation of production waste and its reuse in the production cycle. We design the sole mold to minimize manufacturing waste. We are optimizing our processes to minimize resource consumption and the environmental impact of our production, introducing water-based glues, which are harmless to the environment and humans, in our assembly and gluing processes.

We are also committed to research and development for end-of-life shoe recycling, providing alternative and more sustainable solutions for the disposal of end-of-life footwear. We collaborate with brands to develop customized solutions for the production of more sustainable shoe soles, maintaining high quality and performance standards.

If your company is looking for innovative solutions for sustainable sole molding, contact us to discover our latest technologies and materials!

19/03/2025

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Bioplastics & Recycled Plastics: How Sustainable Materials Are Reshaping Footwear

They are revolutionizing footwear sole production, offering sustainable solutions without compromising quality or performance. From bio-based TPU to recycled EVA,

Pu.Ro. Joins ZDHC’s Roadmap to Zero: A Strategic Commitment to Sustainable Chemical Management

Excellence and innovation have always been at the heart of everything we do. In today’s global context, we firmly believe

Send us a message

Pu.Ro. Wins the Best Value Award Marche 2024: Celebrating Innovation and Excellence

We are proud to announce that Pu.Ro. has been honored with the Best Value Award Marche 2024, recognizing our role as one of the top-performing businesses in the Marche region for generating economic value.

On December 9, 2024, at the Confindustria Ancona headquarters, Pu.Ro. was celebrated alongside 44 other companies chosen from over 11,800 examinate. Organized by Imprenditore Smart® with the support of Stone S.p.A., the Best Value Award Marche 2024 highlights businesses demonstrating outstanding growth and economic impact.

Innovation at the Heat of Our Vision

At Pu.Ro., our mission has always been clear: to deliver solutions that combine design, functionality and quality. Every project is an opportunity to innovate and exceed expectations. This philosophy has positioned us as a trusted partner in the competitive world of luxury footwear manufacturing.

Our Two Pillars

Our growth and the recognition we have received are based on two fundamental pillars:

Focus on R&D:

we continuously invest in improving materials and molding processes, tackling every project with a commitment to customization and innovation. This allows us to deliver cutting-edge solutions that help our clients stay ahead of the competition.

A customer-centric approach:

we provide end-to-end support, from concept and prototyping to full-scale production. By tailoring our services to each client’s needs, we build long-term partnerships rooted in trust and shared success.

Looking Forward

Receiving the Best Value Award Marche 2024 inspires us to continue innovating, collaborating with our clients and delivering excellent footwear soles and accessories. We are ready to take on new challenges and seize future opportunities.

A heartfelt thank you to our team, partners and clients. Your trust and support make everything we do possible.

Let’s Collaborate!

Looking for innovative solutions for your next footwear project? Contact us and discover how Pu.Ro. can help bring your vision to life with expertise and creativity.

12/12/2024

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Bioplastics & Recycled Plastics: How Sustainable Materials Are Reshaping Footwear

They are revolutionizing footwear sole production, offering sustainable solutions without compromising quality or performance. From bio-based TPU to recycled EVA,

Pu.Ro. Joins ZDHC’s Roadmap to Zero: A Strategic Commitment to Sustainable Chemical Management

Excellence and innovation have always been at the heart of everything we do. In today’s global context, we firmly believe

Send us a message

Mold Maintenance and Adjustment in Footwear Sole Molding

Why Keeping Molds in Optimal Condition Is Essential.

In the injection molding industry for shoe sole production, the quality of the final product relies significantly on the efficiency and precision of the molds used. Molds are the core tool in molding process, and, like any equipment, they require proper care to ensure peak performance.

In this article, we’ll examine why regular mold maintenance and regular adjustments are essential in shoe sole molding and the tangible benefits they bring to companies in the plastic molding for footwear.

1. The Quality of the Sole Depends on the Mold

In the early stages of production, precise mold setup is crucial to verify functionality and make any necessary improvements. During production, regular mold maintenance helps prevent aesthetic and structural defects in the soles. Poorly maintained molds can result in issues such as:

Burrs and flashes
Thickness variations
Surface irregularities

These defects can compromise not only the appearance, but also the technical performance of the sole, potentially affecting customer satisfaction. In a competitive and quality-driven sector like luxury footwear, preventing these defects is critical. Implementing a preventive maintenance program for molds reduces waste, avoids costly rework and supports consistent quality control.

2. Extending Mold Lifespan

Molds are subject to wear and tear due to the high temperatures and intensive use typical of the plastic injection molding process. Preventive maintenance allows companies to detect issues such as wear, corrosion or material buildup, leading to several key advantages:

Extended mold lifespan
Reduced need for costly replacements
Optimized economic efficiency across the entire production cycle

3. Minimizing Downtime

Timely mold adjustments are essential to minimize machine downtime, ensuring an uninterrupted production flow and reducing costs associated with unexpected breakdowns. A preventive maintenance plan that includes regular inspections and repairs enable companies to:

Identify potential issues early on
Reduce the risk of unexpected breakdowns that can halt production and cause delays in delivery schedules

By proactively managing maintenance, companies can maintain their productivity and uphold high standards in lead times, essential for meeting the fast-paced demands of the luxury footwear market.

4. Ensuring Precision and Consistency

Well-maintained molds guarantee the precision needed to meet dimensional tolerances and technical specifications in the shoe sole production. In a market where accurancy and consistency are essential for customer satisfaction, regular mold maintenance and adjustments help companies to produce high-quality, standardized soles.

Well-maintained molds are vital for achieving the precision and consistency needed in luxury shoe sole production. Our in-house team of specialists ensures that molds always meet the strict dimensional tolerances required, enabling us to achieve:

Standardized quality across all soles
Consistency and repeatability across production batches

In the luxury footwear industry, where precision and consistency are non-negotiable, regular maintenance helps sustain high-quality standards and ensures that each product meets the expectations of discerning clients.

A Strategic Investment in Competitiveness

For companies dedicated to shoe sole molding for high-end footwear brands, keeping molds in peak condition is a strategic investment that extends beyond operational costs. Regular maintenance and timely adjustments reduce waste, optimize production efficiency and support reliable delivery times.

Thanks to our in-house tool shop and dedicated team specializing in mold maintenance and adjustment, we can perform swift interventions that minimize downtime. This in-house capability allows us to maintain consistent quality without depending on external suppliers, ensuring efficient, prompt mold management and safeguarding production timelines.

04/11/2024

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Bioplastics & Recycled Plastics: How Sustainable Materials Are Reshaping Footwear

They are revolutionizing footwear sole production, offering sustainable solutions without compromising quality or performance. From bio-based TPU to recycled EVA,

Pu.Ro. Joins ZDHC’s Roadmap to Zero: A Strategic Commitment to Sustainable Chemical Management

Excellence and innovation have always been at the heart of everything we do. In today’s global context, we firmly believe

Send us a message

Stepping into Sustainability: The Impact of Biopolymers in Plasting Molding for Footwear

Like the entire fashion system, the footwear industry is increasingly moving towards an eco-friendly production process to reduce environmental impact and meet sustainability challenges. Let’s explore what new biopolymers are and how they can be integrated into the creation of a shoe sole.

Many fashion brands are transitioning to a more eco-friendly approach to minimize their environmental footprint and cater to the growing demand from consumers for sustainable products. The footwear industry is also aligning itself with these needs and adapting to new trends, with the goal of transforming its processes and business models into a more sustainable practices.

A Definition: Not Bioplastic, But Bioplastics

Firstly, let’s provide a brief overview of what bioplastics are. As defined by European Bioplastics, the term bioplastics refers to a type of plastic that can be biodegradable, bio-based or possess both features. This description encompasses a broad family of polymers categorized into various types.

To be more precise, bioplastics can:

– Originate (partially or entirely) from biomass and not be biodegradable (e.g., bio-PE, bio-PP, bio-PET);

– Originate (partially or entirely) from biomass and be biodegradable (e.g., PLA, PHA, PHB, starch-based plastics);

– Entirely originate from non-renewable raw materials and be biodegradable (e.g., PBAT, PCL, PBS).

Bioplastics are classified based on their production and recycling process. Two main polymer categories are generally used: bio-based plastics and biodegradable plastics.

Bio-Based and Biodegradable Plastics

Bio-based plastics consist of materials whose components come entirely or partially from renewable and plant-based raw materials. These materials include biopolymers created from biomass, primarily composed of sugars (sugar cane), starches (corn, wheat, sweet potatoes), cellulose, algae, vegetable oils, and more. This category includes materials mainly used in food packaging and textile fibers.

30/11/2020

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Bioplastics & Recycled Plastics: How Sustainable Materials Are Reshaping Footwear

They are revolutionizing footwear sole production, offering sustainable solutions without compromising quality or performance. From bio-based TPU to recycled EVA,

Pu.Ro. Joins ZDHC’s Roadmap to Zero: A Strategic Commitment to Sustainable Chemical Management

Excellence and innovation have always been at the heart of everything we do. In today’s global context, we firmly believe