Interview about GreenPlax Footwear, winner of the A' Footwear, Shoes and Boots Design Award 2020
Trying to protect the ecosystem and the environment, as well as to leave beautiful mother earth for future generations, Ccilu spent 5 years developing GreenPlax technology and created the first-ever footwear collection made primarily out of plastic bottles retrieved from the oceans. The recycled plastic bottles are used for every major component in the shoes, uppers, insoles, and outsoles, turns the hazardous wastes into green material, moreover, the GeenPlax is bottomed-up with 100+ independent and resilient dots to deliver barefoot comfort.
View detailed images, specifications, and award details on A' Design Award & Competition website.
View Design DetailsThe development of GreenPlax Footwear began in April 2014 with the goal of addressing the severe issue of plastic pollution. Over five years, we focused on intensive research and innovation, starting with methods to retrieve, sort, and clean ocean-recovered plastic bottles. The biggest challenge was creating a process to transform the recycled bottles into usable materials for all major shoe components. By 2019, we had successfully developed a multi-step process: shredding the bottles, converting them into pellets, and then further processing these into fibers for fabrics and threads. This extensive journey culminated in the creation of the world’s first shoe where even the outsoles, along with the uppers and insoles, are made primarily from recycled plastic bottles, demonstrating a significant leap in sustainable footwear manufacturing.
Our inspiration came from the alarming reports on the impact of plastic pollution, particularly the millions of plastic bottles discarded every minute, many of which end up in the ocean. The health and ecological consequences drove us to find a solution that not only recycles plastic but also prevents it from polluting our environment. Overcoming technical challenges involved extensive experimentation with material combinations, particularly merging RPET with EVA. We had to innovate new manufacturing techniques to ensure the materials retained high-performance characteristics such as flexibility, lightweight, and durability, while maintaining eco-friendliness.
The SKIVE-ON technology is a groundbreaking design that incorporates over 100 independent, resilient dots in the outsole, enhancing comfort by mimicking the sensation of walking barefoot. This ensures excellent flexibility, lightweight performance, and grip, which are essential for modern footwear. These dots are made using a blend of recycled plastic pellets and EVA, staying true to our eco-friendly mission. The design reduces material usage while maintaining structural integrity, further enhancing the product’s sustainability without compromising user comfort.
We approached the process methodically, starting with sorting and cleaning the bottles to ensure high-quality raw material. Then, we shredded the bottles into smaller pieces, which were converted into perfectly shaped pellets. These pellets were processed further into fibers for fabric production and also mixed with EVA for the outsole. Each step was refined through rigorous testing to ensure that the final materials met both environmental standards and performance requirements. Collaboration with material scientists and engineers played a critical role in optimizing the process to maintain consistent quality and sustainability.
Scaling this technology involves building partnerships with organizations focused on ocean cleanup and expanding our recycling infrastructure to process larger volumes of plastic waste. Additionally, we plan to streamline the manufacturing process to increase efficiency and reduce costs. By collaborating with retailers and eco-conscious brands, we aim to make GreenPlax technology a standard for sustainable footwear. Our goal is to expand the application of this technology to other types of footwear and accessories, further amplifying its environmental impact while preserving our commitment to performance and quality.
The breakthrough came after years of trial and error in material blending. The primary challenge was achieving the right balance between RPET’s structural properties and EVA’s flexibility and cushioning. The turning point was discovering a specific temperature and processing technique that allowed the two materials to bond effectively without compromising their individual qualities. This innovation enabled us to mold RPET into durable outsoles, marking a major milestone in sustainable footwear technology.
Winning the Silver A’ Design Award brought widespread attention to the possibilities of sustainable design, inspiring industry leaders to rethink their reliance on virgin materials. GreenPlax Footwear has demonstrated that recycled materials can deliver both performance and aesthetic appeal. It has set a new benchmark for eco-friendly manufacturing, encouraging competitors and collaborators alike to prioritize sustainability and innovate in their production methods.
Balancing environmental concerns with material science required a clear vision and interdisciplinary collaboration. We conducted thorough research into the lifecycle of plastic waste and its environmental impact while simultaneously developing innovative methods to repurpose this waste into high-performance materials. The team maintained a focus on commercial viability by incorporating consumer feedback and emphasizing comfort, durability, and style. This ensured that the product appealed to eco-conscious buyers without compromising on market competitiveness.
For the next generation, we aim to further optimize material efficiency, reduce the energy footprint of our manufacturing process, and explore additional recycled materials. We’re also looking into biodegradable alternatives and ways to enhance the recyclability of GreenPlax Footwear itself. Future designs may incorporate smart features for improved functionality, keeping sustainability at the core of our innovation.
GreenPlax Footwear is proof that sustainability and performance can coexist, setting a new standard for the industry. We anticipate that our technology will drive a shift toward the widespread adoption of recycled materials and sustainable practices. By proving the commercial and ecological benefits of sustainable footwear, GreenPlax encourages other brands to invest in eco-friendly innovation. We hope this will lead to industry-wide changes, from sourcing and production to consumer education and end-of-life recycling.
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