PLIXXENT and Bata Industrials are proud to highlight the successful development and implementation of an innovative bio-based polyurethane (PU) system for protective footwear, combining sustainability with high performance.
Development Timeline and Milestones
The collaboration between PLIXXENT and Bata Industrials began in 2020 with the development of a high-dynamic PU system without bio-based content. Building on this foundation, a first-generation bio-based system featuring high rebound properties was
introduced in 2023. In 2025, a second-generation system was launched, maintaining the same bio-content while offering improved processing performance.
Following Bata Industrials request for a bio-based solution, both partners adopted a fast-track development approach. The first-generation system was successfully brought into manufacturing.
Joint Development Approach
The bio-based systems were developed through close collaboration. Bata Industrials initiated the request for sustainable materials, while PLIXXENT led the formulation development. Extensive testing was conducted at PLIXXENT’s technical center in Oldenburg using original Bata Industrials molds. After successful validation, the system was seamlessly transferred to Bata Industrials production facilities.
Sustainability and Bio-Content
The current system contains bio-based raw materials. The technology also allows for further increases in bio-content, offering future potential for even more sustainable solutions.
Bata Industrials move toward bio-based systems reflects its commitment to sustainability and differentiation within the protective footwear market.
Performance and Manufacturing Advantages
The bio-based PU system delivers performance equivalent to conventional systems, with no compromise in key properties. It offers:
- High rebound characteristics
- Smooth and efficient processing, especially in the second generation
- Faster cycle times (with further optimization potential through equipment
upgrades) - Extremely low reject rates, approaching zero
The underlying bio-based technology is part of PLIXXENT’s PUre³ Solutions® portfolio. The specific formulation developed in this collaboration has been customized for Bata Industrials and its production environment.
