Strengthening the business value chain

Synthelast and PIKOKAIZEN complete the VAL-rPU-CALZADO project to recycle polyurethane soles from healthcare footwear and incorporate new recycled materials into footwear manufacturing, supported by AVI and funded by the European Union.

SYNTHELAST S.A., together with PIKOKAIZEN S.L., has carried out a project supported by the Valencian Innovation Agency (AVI) under the «Strengthening the business value chain» programme, funded by the European Union. Its objective was to develop new technologies and innovative processes for recycling polyurethane (PU) soles from healthcare footwear collected from hospitals, recovering primary components such as polyol to synthesise new recycled polyurethanes and incorporate them into conventional footwear manufacturing processes. The successful completion of this project has enabled recycled PU material to be reintroduced into the value chain, reducing waste sent to landfill and incineration and contributing to the circular economy in the footwear industry. This integrated solution reduces the environmental impact of a sector responsible for thousands of tonnes of discarded PU each year in Spain, while delivering clear competitive advantages: raw material savings (a 20–30% reduction in formulation costs), diversification of supply sources through alternative streams such as mattress foams and automotive seats, and anticipated regulatory compliance with initiatives such as the Circular Economy Strategy (2020), the WEEE Supplements Directive (2012/19/EU) and circular economy targets for 2050. SYNTHELAST S.A. developed complete processes to obtain recycled PU, including the recycling methods and component formulations needed to produce recycled PU with good physical properties. PIKOKAIZEN S.L. developed working methods adapted to this recycled PU and designed footwear models and systems suited to the recycled material. Project details Beneficiary: SYNTHELAST S.A. Project title: Recovery of footwear waste to develop new polymeric materials. File reference: INNCAD/2023/73. Grant: €214,170.60. Results achieved 1. Development of a method for recycling PU healthcare footwear collected from hospitals. 2. Development of formulations using recycled PU to manufacture footwear soles. 3. Development of a manufacturing process for footwear soles using recycled PU as the raw material. 4. Development of a footwear manufacturing process using recycled PU soles. INESCOP collaborated throughout the research stage and in validating the characteristics of new footwear manufactured with up to 45% recycled PU. UPV validated physical properties, and ONDYTEC coordinated project implementation. Supported by Generalitat Valenciana and the Valencian Innovation Agency (AVI). Funded by the European Union.