Independent research

Composite toe cap of safety shoes
impact to environment

This document evaluates composite toe cap materials not on biodegradability — which is limited across all structural materials — but on carbon origin, process energy, recyclability, and regulatory resilience.

Published December 2025 Kessin Sustainable · Berlin, Germany Available in 7 languages
~95% of epoxy composites end up in landfills
73% of consumers willing to pay premium for sustainable
41% of Bio-Toe bio-based materials come from bio waste
9× lower energy in the forming step vs epoxy cure
What the research covers

An honest comparison of toe cap materials

Every year, around 10 billion pairs of safety shoes are produced worldwide — most equipped with composite toecaps made from glass fiber and epoxy. Although mechanically effective, these epoxy-based composites are non-recyclable, non-decomposable, and associated with high energy consumption and significant CO₂ emissions throughout their life cycle.

This research introduces Bio-Toe as a sustainable alternative — manufactured from a polyamide formulation containing 41% bio-based nylon derived from non-food biomass. It evaluates materials across four dimensions:

01
Carbon origin
Where the carbon in the material comes from — fossil fuel reserves or renewable biomass sequestered from the atmosphere.
02
Process energy
Primary energy demand from cradle to gate. Bio-PA56 injection moulding takes ~65 seconds vs 30 minutes for epoxy cure — a 9× energy gap in the forming step alone.
03
Recyclability
Bio-PA56 enables mechanical recycling — re-grind, melt, injection mould — recovering 80–90% of polymer mass across 5–7 cycles. Epoxy thermosets cannot be remelted; only fibers can be partially recovered, once.
04
Regulatory resilience
EU regulatory roadmap (2026 onward) tightens restrictions on epoxy hardeners and CMR-classified chemicals. Bio-PA56 already meets upcoming bio-content mandates in EU and US markets.
Key finding — Energy
MaterialEnergy (MJ/kg)
Bio-based PA5660–80
Glass fiber + epoxy115–155
Carbon fiber + epoxy320–390

Indicative primary energy demand, cradle-to-gate

Key finding — Recycling cost
MaterialCost per kg
Bio-PA56~€0.30
Epoxy composite€1.50–3.00

Recovery cost comparison — compounding vs solvolysis

Overall assessment

"Bio-based PA56 toe caps offer the most favorable balance currently achievable among commercially available toe-cap materials, without compromising certified safety performance."

Download the research

Available in 7 languages

The full research paper is freely available. Select your language below.

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English
Research_en.pdf
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Deutsch
Research_de.pdf
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Italiano
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Nederlands
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Dansk
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Certifications

Supporting documents

Every claim in the research is backed by independent third-party certification. The documents below are available for download for specification and procurement purposes.

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EN ISO 22568-2 Test Report
Impact protection test for safety footwear toe caps. Conducted by Intertek Testing Services Shenzhen.
Download
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41% Bio-based Content Report
Bio-based carbon content verified at 41% of total organic carbon. Conducted by BETA analytical laboratory.
Download
Sources

References