Henkel Draws On Adhesive Expertise to Advance Green Footwear

The sports footwear industry is experiencing a significant transformation. As consumer demand for high-performance, sustainable shoes grows and regulatory pressures intensify, manufacturers are seeking solutions that can simultaneously balance efficiency, safety and environmental responsibility.

Adhesive technologies – the glues that bond shoe components – are central to this shift.

Henkel, a global leader in these technologies, is at the forefront of the move towards sustainability.

The company is driving progress by reducing volatile organic compounds (VOCs), optimising production processes and cutting carbon emissions.

Sportswear & sustainability: The challenges of footwear production

Footwear production is a complex process, often involving numerous materials and requiring intricate assembly methods.

The industry is also a major contributor to global emissions, with the fashion sector accounting for 4% of total CO₂ emissions. A single pair of running shoes can produce 13.6 kilograms of carbon dioxide, making sustainability a key concern for brands and manufacturers alike.

One of the primary challenges faced by these organisations is their dependence on solvent-based adhesives, which release VOCs into the air, posing health risks to factory workers.

Additionally, SGS reports that VOCs are not only a health risk during production but can continue to be emitted long after the shoes are completed.

Henkel’s approach to footwear manufacturing focuses on replacing these harmful chemicals with water-based alternatives, which eliminate emissions without compromising performance.

It is clear that manufacturers must address the issue of 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.”

Cutting emissions through adhesive innovation

Henkel’s R&D efforts have led to the creation of water-based adhesives that significantly reduce emissions and enhance efficiency.

For example, the company’s Aquace range eliminates VOCs while maintaining strong bonding performance, providing 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.

In addition to improving adhesive composition, Henkel is streamlining production by reducing the number of steps required in the bonding process.

The company’s two-in-one solutions eliminate the need for separate priming, cutting energy use and carbon emissions.

Meanwhile, its CoolX range allows manufacturers to lower drying temperatures from 50°C to 35°C, reducing energy consumption and enabling the use of more environmentally-friendly materials.

Considering that approximately 50% of a shoe’s carbon footprint is generated during manufacturing, these innovations offer significant potential for reducing emissions.

Automation & efficiency in footwear production

Footwear manufacturing is traditionally labour-intensive, but automation is increasingly enhancing efficiency and sustainability.

The rising cost of labour, coupled with the need for more precise production methods, is driving significant investment in robotic systems capable of handling complex assembly tasks.

Henkel is actively involved in this transition, collaborating closely with its manufacturers to optimise the production lines used to make its shoes.

Overall, the results have been positive. Henkel is helping brands reduce waste, improve consistency and lower energy consumption.

"We keep our finger on the pulse by collaborating with partners at our growing global network of innovation and application centres," adds 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."

Adhesive technologies & the future of sustainable sports footwear

Looking ahead, the sports footwear industry is poised for further innovation. Brands are exploring bio-based and biodegradable materials, modular designs that facilitate easy recycling and smart shoes that incorporate technology for performance tracking.

Adhesive technologies will continue to be a key enabler of these advancements, ensuring that sustainability does not come at the expense of durability or efficiency.

Henkel’s ongoing investment in research, partnerships and application centres places it at the forefront of this transformation.

The industry's shift towards sustainability is no longer a niche endeavour but an essential requirement, and Henkel's recent efforts are a clear demonstration of this.

"There are many bold ideas bouncing around the shoe market today," Lena concludes, "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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