BASF Advances Polyurethane Recycling to Boost Footwear Circularity

The circularity of the footwear industry is gaining momentum with BASF pioneering chemical recycling solutions for polyurethane, one of the lightest and most high-performing plastics. At SIMAC Tanning Tech in Milan, the company unveiled new recycled materials that maintain the same lightweight and durable properties as virgin plastics. Soles, uppers, and shoes made from cast or thermoplastic polyurethane (TPU) can be recycled through pyrolysis and gasification, with future potential for specific chemical recovery processes. However, logistical and economic challenges remain due to regulatory variations between countries.

BASF’s new Elastollan® RC TPU, made with up to 100% recycled content, represents a key step towards sustainable footwear production. The company also demonstrated automated polyurethane processing to produce midsoles in a single step and introduced the “Detonate” sole concept using expanded TPU for adjustable density and high performance. With 24 billion shoes produced globally in 2022, most ending in landfill or incinerators, footwear recycling faces major obstacles due to complex material compositions and contamination.

As the European Commission works on an extended producer responsibility directive, companies must also address competition from low-cost fast fashion. Industry experts stress that circularity will require not just material innovation but also efficient logistics, regulatory alignment, and sustainable business models. BASF’s initiative marks an important first step, signalling how integrating technology, policy, and market strategies can help transform footwear into a model of circular economy.

Source: BASF