Orclever Proceedings of Research and Development

The Green Step Upper: A Novel Sustainable Bonding Method Replacing Solvent-Based Adhesives in Footwear Upper Assembly

Baris Bekiroglu

Eren Perakende ve Tekstil A.Ş.

https://orcid.org/0009-0001-4010-6956

Mustafa Yener

Eren Perakende ve Tekstil A.Ş.

https://orcid.org/0009-0004-0342-6557

DOI: https://doi.org/10.56038/oprd.v7i1.708

Keywords: Solvent-Free Adhesive Technology, Footwear Manufacturing Innovation, Sustainable Production, VOC Reduction, Process Optimization, Adhesive Tape System

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Abstract

The Green Step Upper project introduces an innovative, solvent-free adhesive application technology designed to transform stitching preparation processes in footwear manufacturing. Traditional methods rely on double-sided application of solvent-based adhesives, resulting in high VOC emissions, increased labor dependency, inconsistent quality, and environmental burdens. This project eliminates these limitations through a specially engineered single-surface adhesive tape system that provides stable fixation, homogeneous bonding distribution, and improved process efficiency. The research covers material selection, ergonomic apparatus design, prototype development, and performance testing across different upper materials. Results demonstrate a complete removal of solvent use, a significant reduction in operational time and labor costs, improved product consistency, and zero VOC emissions, enabling fully sustainable production. The proposed system offers a scalable and commercially viable model that can be adopted by both domestic and international manufacturers, contributing to national competitiveness while supporting global sustainability targets.

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Author Biography

Baris Bekiroglu, Eren Perakende ve Tekstil A.Ş.

Baris Bekiroglu is an R&D Executive in the Footwear Division at Eren Perakende, where he leads research and development activities for Converse (a Nike-owned brand) footwear manufacturing. His responsibilities include establishing advanced material and process capabilities for vulcanized footwear production, overseeing the setup of rubber compounding and vulcanization operations, and implementing innovative manufacturing techniques acquired through technical exchanges with Converse facilities in Vietnam. He also contributes to digital transformation initiatives by integrating process flow charts, ERP systems, and optimized production workflows. With over three years of experience in industrial footwear R&D, his work focuses on sustainable materials, process efficiency, and the development of next-generation adhesive and assembly technologies.

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