Minimising Waste: Buchanan Orthotics Embraces More Sustainable Insole Manufacturing

At Buchanan Orthotics, we are dedicated to providing exceptional foot orthoses while prioritising environmental responsibility. Traditional milling techniques used for insoles can generate considerable waste.

As seen in the image, a split-density block used for milling can weigh a substantial 805g. However, after creating a single pair of insoles, only around 110g of usable material remains. This translates to a significant 76% waste factor.

A split block of EVA with a High density back and medium density forefoot

 

The insoles after being milled then cut out the block

Furthermore, shipping these large EVA blocks contributes to a larger carbon footprint compared to the transportation of lightweight spools of filament used in 3D printing.

Fortunately, technological advancements are paving the way for more sustainable solutions. 3D printing insoles with TPU (thermoplastic polyurethane) reduce waste dramatically. Through 3D printing, we can typically generate just 3g of waste per pair of insoles.

Waste from 3d printing a pair of insoles in TPU

To minimise the waste from EVA milling we have actively invested in newer, more energy-efficient milling machines. As well as using advanced nesting software to optimise the number of insoles that can be milled from a single EVA sheet, further reducing waste.

This substantial decrease in waste allows us to deliver high-quality, custom-made insoles while minimising our environmental impact. Buchanan Orthotics is committed to responsible manufacturing practices and continuously seeks methods to lessen our environmental footprint.