Jute-thermoplastic
composite based shoe components (toe puff & counter stiffeners)
have been developed under a project launched by the Advanced
Composites Mission in partnership with APL Polyfab (P) Ltd.,
Kolkata with technology support from the Indian Jute Industries
Research Association (IJIRA), Kolkata.
The project aimed at developing jute-thermoplastic
composite components such as toe puff, counter stiffener,
insoles etc. for footwear. The toe puff & counter stiffener
are inserted between the leather and lining material for the
purpose of stiffness, shape retention etc. While toe puff
is used in front portion, counter stiffener is used in backside
of footwear. The jute composite components are aimed to replace
the ones made of leather, leather board, synthetic material,
cellulose/paper pulp etc. with reduced cost. Besides, they
also provide good strength and compatibility with thermoplastic
hot melt adhesives thus leading to better shape retention,
mouldability, flexibility etc. IJIRA, Kolkata assisted in
providing all the related information on jute properties,
selection of raw materials and their formulation considering
the end property requirements, fabrication and testing of
prototypes.
The low cost jute-thermoplastic components
would cater to a large segment of shoe manufacturers, who
have been importing the semi-finished sheets due to non-availability
of required quality & volume of such components.
The project comprised of two phases. The
first phase involved the impregnation of woven raised jute-cotton
fabric by a water-based polymeric emulsion. The continuous
impregnation plant was designed & developed indigenously.
The toe-puff & counter stiffener developed under the first
phase have met the property requirements as per international
standards. A few footwear manufacturers have also found the
product samples satisfactory in actual use. The second phase
involved the complete design and fabrication of the hot melt
adhesive (HMA) system indigenously.
The entire HMA coating system complete with
two stainless steel kettles with agitators for resin mixing,
tray for HMA application with oil heating system, one 650
mm dia-roller & two nos. 400 mm dia rolls complete with
individual drives with motors, control panels, un-winder,
draw rollers, chilling rollers, silicone roller, balancing
idle rolls, etc. was fabricated and assembled within a short
period.
Jute-cotton fabric impregnated with different
emulsion formulations was coated with hot melt adhesives to
cater to major shoe manufacturers as well as the international
market. The technology development exercise for impregnation
of jute-cotton fabric with subsequent HMA coating for toe
puff & counter stiffener for footwear has been a success.
The technology, now protected by a patent by APL Polyfab,
is now available for transfer to prospective entrepreneurs
desiring to manufacture jute-thermoplastic based shoe components
in other countries.
The impregnated jute-cotton sheet would
also find applications in leather purses and similar products.
As HMA coating of jute-cotton fabric is a major value-addition
step, the product is expected to enjoy good market share.
Further, development efforts are underway for extrusion coating
of jute for making filmic type toe puff sheets used for fashion
shoes, children’s and sports shoes with good demand in
the market.
APL Polyfab Ltd., Kolkata has launched the
new product line using 100% indigenous material and technology
at the Delhi International Leather Fair 2002.
