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skived edges would also stick to the upper material, thus
improving the bonding area. The material was also easier to
handle when hot, as it did not stick to the operator’s fingers.
The fact it was made using a powder system with synthetic
fillers and polyester fabric meant it was also recyclable and
thus environmentally friendly.
A final refinement introduced in the 80s was Rhenoprint,
still widely used today. This was totally powder-based and,
although it again contained fillers, there was no longer any
woven element. Where it really scored was the fact that it
could be moulded to the required shape with all edge
reductions included so that no skiving is required. Equally
importantly, it also effectively eliminated all waste as
everything can be re-ground and re-used as prime raw
material.
The RX5000 range, introduced in 2005, took this idea a
stage further by replacing the synthetic fillers with natural
ones. This made the product even more environmentally
friendly as well as totally recyclable. Remarkably, wood and
straw are cleverly used as the basis for these fillers and one
really begins to wonder just what else can be exploited as
fillers in the various materials the footwear industry uses. In
addition, the manufacturing process is entirely solvent-free
and no additional adhesive is required during processing in
the shoe factory.
It also has an exceptionally long open time that can
accommodate delays of up to ten minutes between toe and
seat lasting. This is significant as it reduces the need to reheat
that has been a problem with many thermoplastic puffs, and
counters in the past and saves both time and energy
consumption in the factory.
The latest product innovation is 3700RX Bio and is made
from recycled bio-plastics. It is fully biodegradable and, the
company claims, is therefore an absolutely unique product as
it combines manufacturing efficiency with minimal
environmental impact. Following on from the RX3000 and
RX5000 materials, it is a further stage in taking care of our
environment. The raw materials used to produce it actually
originate in the medical and packaging industries and possess
some very useful features such as total moisture resistance,
hardly any flammability and excellent colour fastness. From a
processing point of view, it again has a long open time and, in
addition, can be softened prior to lasting or moulding at
temperatures as low as 60°C.
Quite how these sources of recycled materials that also
offer technical improvements to the final materials they are
used to produce are identified is something of a mystery to
many of us. Who or what sparks the idea of where to look in
the first place? The fact that it must also take considerable
time and effort is obvious. And time costs money, so it also
takes considerable faith for any company to embark on such
a programme for a final product that the end consumer is
largely unaware of.
Like some other successful companies in today’s footwear
industry, Rhenoflex has nevertheless based its business on
developing ideas and technologies that not only help produce
quality footwear but to also maximise the potential cost
savings that can be made though the use of recycled
materials. When every penny counts, even such relatively
small hidden components as toe puffs and counters can play
their part.
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RECYCLING WHERE LEAST EXPECTED
MARCH/APRIL 2012 | www.footwearbiz.com