The FAIST (Agile, Intelligent, Sustainable and Technological Factory) consortium brings together over 40 Portuguese partners across footwear and leather goods, technology providers and research centres. Running from June 2022 to June 2026, the programme channels about 50 million euros of investment into projects that modernise the industry and sharpen its international competitiveness.

Bolflex in Focus 

Founded in 1991, Bolflex has grown over time to become a leader in the production and transformation of footwear components, primarily rubber soles. This was largely thanks to the company’s constant desire and determination to innovate. 

“Our innovation journey began in 2009. I started producing soles using injection moulding, which was unique at the time. Then, in 2013, I set up a metalworking shop. I bought 3D printers, which are very popular today, but I had already acquired them”, recalls António Ferreira, CEO of Bolflex. Today, the company streamlined all processes into a single structure, thus reducing the development and production time of each product or project. 

The company is also renowned for its zero-waste policy. “I set up a recycling company (RubberLink), fulfilling a dream I had had for many years. I couldn’t comprehend why raw materials were being buried”, he explains.

Under FAIST

With the support of the Portuguese Footwear Technological Centre (CTCP), Bolflex has developed solutions in two key areas within the FAIST framework. 

The first area focuses on Industry 4.0 and includes digitalisation and automated processes that have been developed and implemented by Bolflex either internally or through contracted companies that are not co-promoters of the FAIST project.

 
The second area addresses sustainability by developing R-Skin: a 100% recycled sheet material that combines multiple waste streams and is intended as a sustainable alternative to animal leather for use in footwear. The company is leading this work with the aim of maximising waste incorporation while maintaining the material’s functional and aesthetic properties.

FAIST Outcomes

“FAIST has really helped us”, stated the CEO of Bolflex. The project has supported the company’s digital transformation by enabling the progressive implementation of software and digital solutions across the production chain, from raw materials warehousing to finished goods. These solutions have even been integrated into the accounting system.

“Before we had these programmes, it was almost entirely up to the worker how long the machine would work at its current speed”. Now, “supervisors instruct the machines via a reference system. Employees cannot touch the machines. The programme itself defines what needs to be done”, said António Ferreira, highlighting more efficient control of the production process.

Regarding the development of R-Skin, the material is already commercially available. Further development will focus on increasing other types of waste and expanding its potential applications. Additional assessments are expected to confirm the feasibility of producing high-quality recycled materials for use in footwear.

Although the concept originated within the company prior to FAIST’s involvement, the project has provided a framework for advancing the material beyond its initial market-ready state. FAIST has particularly supported continued optimisation and the demonstration of multiple applications, including those presented at a project-dedicated workshop.

You can explore more about the FAIST project here. 

Visit the Bolflex website for more information.