The Future of Eco-Conscious Footwear Manufacturing

Lenzing AG, Santoni SPA and Procalçado SA bring their expertise together to create a sustainable shoe entirely made from 100% biodegradable and renewable materials.

Following on from the first Innovation Showcase at NEONYT in January 2019, the zero-waste shoe comes to Techtextil & Texprocess May 2019 and has been developed further to be even more circular. Find out more about the collaboration at the Fashionsustain conference in the Texprocess Forum, Hall 4.1 A02 on the 14th May from 13:00 to 13:45, or make your way to the Innovation Showcase in Hall 4.1 C46 from the 14th to 17th May – and read up on the companies, materials and technologies below.

 

Lenzing AG

With 80 years of experience Lenzing sets the global standard for wood-based cellulose fibres, made from renewable FSC- or PEFC-certified wood with environmentally-friendly and innovative technologies.

The footwear showcase highlights Lenzing’s award-winning TENCEL™ lyocell fibre technology used for the shoe upper, lining, laces, sewing threads insole and outsole. Produced in a closed loop process, TENCEL™ fibres are completely biodegradable and require significantly less water, land and chemicals than comparable fibres, resulting in very low emissions while contributing to the circular economy.

Each stage of the manufacturing process is displayed from wood to pulp, fibre to yarn, finished upper to shoe. Under certain conditions at the end-of-life the upper fully reverts back to nature.

 

The X Machine by Santoni SPA

Premier circular knitting machine manufacturer Santoni is a pioneer in seamless technology. Being free of seams eliminates the need to cut and sew fabrics – and thereby waste – as well as speeding up finishing times and reducing labour. The high-tech knitting machines can incorporate a variety of weaves, densities and elasticities within a single garment to improve fit and support around the body.

The Santoni X MACHINE was specially developed to create seamless, knitted footwear using a revolutionary 3D intarsia technology that maps the foot for perfect fit and form, besides offering unlimited patterns and colour combinations.

For the Showcase, the X MACHINE knitted TENCEL™ fibres into one-piece uppers, complete with eyelets, ready for immediate application onto the sole. What’s more, each lightweight breathable upper is produced in record time: from 5 to 7 minutes per piece.

 

ForEver® by Procalçado SA

For over 45 years Procalçado have been making soles under the brand of ForEver® for some of the most recognised shoemakers of the world. Currently producing over 6 million pairs of soles a year, Procalçado specialises in tailor-made solutions in design, innovation, technology and materials.

The showcase features the ForEver® Biodegradable Thermoplastic with TENCEL™ sole solution. Allied with TENCEL™ lyocell powder, the Biodegradable Thermoplastic sole highlights that it is possible to minimise usage of non-renewable raw materials for a more sustainable approach.

 

Title Image: Daniel Gebhardt

 


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