Inside the Production of Bio-Based Soles: From BASF Materials to Finished Products
Created on 10.15
Introduction – Precision Meets Sustainability
In today’s footwear industry, sustainability and performance are no longer competing priorities — they go hand in hand. As brands commit to reducing their carbon footprint and using more renewable materials, bio-based soles have become one of the most effective ways to achieve those goals without compromising on comfort or durability.
At Lebai Bio-based Shoe Sole Co., Ltd., we combine cutting-edge bio-based materials from BASF with advanced manufacturing processes to create soles that meet the highest standards of performance, comfort, and environmental responsibility. From the selection of raw materials to quality testing, every step of our production is guided by the principles of innovation, precision, and sustainability.
Step 1: Selecting Premium BASF Bio-Based Materials
The foundation of every great sole lies in its materials. That’s why we partner with BASF, one of the world’s leading chemical innovators, to source the most advanced bio-based polymers available today.
BASF’s product portfolio includes high-performance materials such as Elastollan® (Bio-based TPU) and Ecovio®, which are made partly from renewable plant-based feedstocks like corn or castor oil. These materials offer the same resilience, flexibility, and abrasion resistance as conventional TPU or PU, but with a significantly lower environmental impact.
Bioplastics - Definition
Elastollan N series BIO Ester TPU
Elastollan N 11 series BIO Ether TPU
Elastollan N SP B series BIO Ester TPU
Elastollan N portfolio
Each batch of BASF bio-materials we use comes with traceability documentation and sustainability certifications, ensuring transparency from raw source to final product. This gives our clients — from footwear brands to OEM partners — full confidence in both performance and environmental integrity.
Step 2: Precision Engineering and Formulation
Once the materials arrive, our R&D team customizes the formulation based on each client’s design and performance requirements. Whether the goal is lightweight flexibility for a running shoe or high rebound elasticity for a lifestyle sneaker, we fine-tune the bio-polymer ratio, density, and hardness to achieve the ideal balance.
Below, I will present to you our sustainable solutions provided by BASF PU.
BIO PU system
BIO midsole system
BIO insole system
BIO insole system
New development
New development
Cold curing approach
This precision in formulation ensures that every pair of soles meets the comfort and durability expectations of international footwear brands.
Step 3: Manufacturing the Soles
Our manufacturing process is designed for efficiency, consistency, and sustainability. The main production methods include:
Below, I will introduce to you our production process and equipment
PU process and machin
Throughout production, we employ closed-loop material management systems to minimize waste and reuse leftover compounds. Temperature and pressure controls are automatically monitored to ensure uniform density and texture across batches.
By leveraging BASF’s process-compatible bio-based materials, our factory can seamlessly integrate sustainable polymers into existing production lines — without the need for costly retooling or performance trade-offs.
Step 4: Quality Testing and Performance Validation
Sustainability means little without reliability. That’s why every sole undergoes comprehensive testing before it leaves our factory.
Our in-house laboratory and third-party partners conduct evaluations covering:
l Abrasion Resistance: To ensure long-lasting wear performance.
l Flex and Bend Tests: To simulate repeated motion and stress.
l Tensile Strength: To confirm durability and deformation resistance.
l Yellowing and UV Resistance: For color stability over time.
l Rebound and Compression Recovery: To measure comfort and responsiveness.
Each test result is carefully documented, ensuring that our clients receive consistent, verifiable quality with every shipment.
For global brands, this level of control and documentation supports their ESG and product safety compliance — a critical factor in supply chain reliability.
Step 5: Finishing, Packaging, and Delivery
Once approved, soles are finished according to client specifications — from texture patterns and logos to color customization. We offer precise color matching using eco-friendly pigments and coatings compatible with bio-based polymers.
Finished products are packed with sustainability in mind: recycled or recyclable packaging materials, optimized carton sizes, and eco-labeling for traceability. Our logistics team works closely with clients to ensure on-time delivery while minimizing carbon emissions through efficient shipment planning.
Commitment to Continuous Improvement
The footwear industry is evolving rapidly, and so are we. Our team collaborates closely with BASF’s R&D centers to test next-generation materials — including higher bio-content TPU and biodegradable elastomer innovations.
By staying ahead of trends and regulations, we help our partners remain competitive in the era of green manufacturing. We regularly update our processes to improve energy efficiency, reduce waste, and enhance recyclability.
Our goal is simple: to make sustainable manufacturing not only possible but profitable for every brand we work with.
Conclusion – Trusted Partners in Sustainable Innovation
From BASF’s renewable materials to the final pair of soles, every stage of our production reflects our dedication to sustainability, quality, and transparency.
Footwear brands worldwide are seeking suppliers who can deliver eco-friendly innovation at scale — and Lebai Bio-based Shoe Sole Co., Ltd. is proud to meet that demand. With advanced equipment, skilled engineers, and BASF-backed bio-based materials, we help brands take meaningful steps toward a cleaner, greener future.
Step into sustainability — one sole at a time.
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