Manufacturing of Shoe Soles Utilizing Corn Cobs as Main Component

The footwear industry creates a large amount of waste, with approximately 300 million pairs of worn-out shoe soles ending up in landfills, with each pair taking 30 to 40 years to degrade. Meanwhile, corn is the most widely grown grain on the planet, which produces a lot of agricultural waste. About four million tons of grain maize and 0.96 million tons of corn cobs are produced per year in the Philippines alone. Studies discovered that corn waste can be regarded as one of the best raw materials, while polyurethane foam can be used as a binding ingredient. This study developed shoe soles made from corn cobs and polyurethane foam. Various testing procedures have been conducted to evaluate the abrasion, thermal resistance, water absorption, and performance of the product. A soil degradation test was conducted to determine the disintegration of the product after its lifetime of use. Upon analyzing the results, the findings indicate that 60% milled corn cobs and 40% polyurethane foam constitute the optimal product composition. Regarding the product feasibility, it can be manufactured as long as it goes through the processes of mold design, mold engraving, mold installation, weighing, mixing, and injection molding.