The recycled rubber base used to produce ExtraLife Insoles, Midsoles, and Outsoles is obtained from End-of-Life Tires using an advanced technology called thermo-mechancial devulcanization.
Primarily, truck tires are targeted for producing the recycled rubber base since the original rubber compound formulation of truck tires uses high proportion of natural rubber and yields maximum durability and performance characteristics like abrasion resistance, tensile strength, tear resistance etc. These are the same quality attributes needed for footwear insoles, midsoles, and outsoles.
Hence, the recycled rubber obtained from truck tires serves as an excellent base rubber in the rubber formulations designed for footwear insoles, midsoles, and outsoles. Additionally, the recycled rubber from truck tires inherently contains carbon-black particles which provides excellent reinforcement to the rubber matrix and provides enhanced durability attributes like abrasion resistance, and tensile strength.
We utilize the recycled rubber base and further re-formulate it with bio-based ingredients and various processing aids to achieve physical and chemical properties desired for various types of footwear applications– safety, outdoor, running etc. Finally, our rubber compound undergoes vulcanization for curing and can take any complex shape or form based on your mold designs.
We do NOT use traditional petroleum based materials like PU (Poly Urethane), EVA ( Ethylene-Vinyl Acetate ), or PE (Poly Ethylene etc. to produce our products. Most suppliers of insoles, outsoles and midsoles end up using these same PU, EVA, PE materials by varying physical properties like density, hardness etc. to create product differentiation but their core or inherent material properties of durability and performance remain the same. Further, these petroleum based materials contribute to the environmental issues like heavy carbon emissions and continued reliance on fossil fuels.
These polymeric materials are lower in cost due to the current levels of mass production but they cannot compare to the inherent durability and performance attributes of ExtraLife's tire-rubber compound, which is originally designed for much greater abrashion resistance, resilience, safety standards etc.
We do NOT employ the conventional methods used for commonly available recycled-tire products like ground rubber, synthetic rubber mulch, synthetic turfs, gym mats, etc. to produce our insoles, midsoles, and outsoles. This conventional method employs the use of grounded rubber and petroleum-based adhesive followed by heat compression to form basic shapes. This conventional method is NOT able to naturally cure or vulcanize the rubber, which limits shapes/ designs capabilities. Furthermore, in this process, the advantageous properties of rubber like compression set, tear resistance etc. are also compromised.
Instead, we use recycled rubber obtained from the long researched and innovative technology of devulcanization. This technology allows us to retain advantageous properties of rubber including resilience, abrasion resistance, durability etc. and form any intricate shape per the mold design and customer requirements
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