Henkel’s Big Step Forward in Sustainable Sports Footwear
The sports footwear industry is undergoing a transformation.
As consumer demand for high-performance, sustainable shoes rises and regulatory pressures increase, manufacturers are looking for solutions that can balance efficiency, safety and environmental responsibility at once.
Adhesive technologies - the glues that hold parts of shoes together - play a crucial role in this shift.
Henkel is one of the world’s leading companies in technologies like these, and the company is leading the charge to sustainability by reducing volatile organic compounds (VOCs), streamlining production and cutting carbon emissions.
Addressing sustainability challenges in footwear manufacturing
Footwear manufacturing is a complex process.
It can involve dozens of materials and require intricate assembly techniques.
The industry is also a significant contributor to global emissions, with the fashion sector responsible for 4% of total CO₂ emissions.
A single pair of running shoes can generate 13.6 kilograms of carbon dioxide, making sustainability a big concern for brands and manufacturers alike.
One of the biggest challenges for these organisations is their reliance on solvent-based adhesives, which release VOCs into the air, posing health risks to factory workers.
What’s more, SGS reports that VOCs aren’t just a risk to health during the manufacturing process - shoes can continue to release VOCs long after they are fully assembled.
Henkel's approach to footwear focuses on replacing these harmful chemicals with water-based alternatives which eliminate emissions without compromising on performance.
It is clear that manufacturers must do something about VOCs, but not all companies yet have the capacity or technology to do so.
“Every business has unique priorities depending on its specific location and factory size,” says Isaac Kim, Senior Product Development Manager at Henkel Adhesive Technologies.
“But all companies need to be adaptable if they want to succeed with sports footwear.”
Reducing emissions through innovative adhesives
Henkel's research and development efforts have led to the creation of water-based adhesives that drastically cut emissions and improve efficiency.
The company's Aquace range, for instance, eliminates VOCs while maintaining strong bonding performance, offering a safer alternative to traditional adhesives.
"We have developed a huge portfolio of water-based solutions that reduce VOCs by up to 100%," explains Jileen He, Innovation Programme Manager at Henkel Adhesive Technologies.
Beyond adhesive composition, Henkel is also streamlining production by reducing the number of steps required in the bonding process.
The company's two-in-one solutions remove the need for separate priming, cutting energy use and carbon emissions.
Meanwhile, its CoolX range enables manufacturers to lower drying temperatures from 50°C to 35°C, reducing energy consumption while allowing for the use of more environmentally friendly materials.
Given that approximately 50% of a shoe's carbon footprint is generated during manufacturing, such innovations hold significant potential for emissions reduction.
Automation and efficiency in footwear production
Footwear manufacturing is a labour-intensive job, but automation is playing an increasing role in improving efficiency and sustainability.
The rising cost of labour, combined with the need for more precise production techniques, is driving a great deal of investment in robotic systems that can handle complex assembly processes.
Henkel is invested in this transition itself, and is working closely with its manufacturers to optimise the production lines on which its shoes are made.
All in all, results have been positive so far. Henkel is helping brands reduce waste, improve consistency and lower their energy use.
"We keep our finger on the pulse by collaborating with partners at our growing global network of innovation and application centres," says Lena Bremshey, Market Strategy Manager for Footwear at Henkel Adhesive Technologies.
"These facilities serve as collaboration hubs for customers and partners to develop sustainable and highly customised solutions."
The future of sustainable sports footwear
Looking ahead, the sports footwear industry is ready and raring to go when it comes to further innovations.
Brands are exploring bio-based and biodegradable materials, modular designs that enable easy recycling and smart shoes that integrate technology for performance tracking.
Adhesive technologies will remain a key enabler of these developments, ensuring that sustainability does not come at the cost of durability or efficiency.
Henkel's ongoing investment in research, partnerships and application centres positions it at the forefront of this transformation.
The industry's move towards sustainability is no longer a niche effort but a necessity and Henkel’s recent endeavours are proof of this.
"There are many bold ideas bouncing around the shoe market today," Lena says, "like the shift to bio-based and biodegradable materials, disassembly of shoes to enable recycling or experiments with smart shoes that collect data."
"Whichever concepts shape the future, sustainable innovations for footwear bonding will play a crucial role because - just like shoes - there is no 'one-size-fits-all' approach."
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