Research & Development at PFI
Whether working on behalf of companies or as part of not-for-profit research projects, PFI has stood for scientific excellence, practical development and technological innovation for decades. Our work combines research, engineering and product development with in-depth industry knowledge.
Find out more about our research and development areas:
Automation technology
Biomechanics
Biotechnology
Biorefinery technology
Testing technology
Footwear technology
Circular Economy & Material Flow Management
Training & Further Education
R&D in the field of automation technology
For high-wage countries such as Germany and most European countries, the key to competitive productivity in an international comparison lies primarily in the automation of processes. This is no longer essential solely for industrial production; it also plays a central role in testing technology, laboratory operations and planning, administration and documentation. With the rapidly growing number of fields of application for artificial intelligence, automation is receiving a further significant boost.
Against this backdrop, the Testing and Research Institute Pirmasens (PFI) has, ever since its founding around 70 years ago, been working on making shoe manufacturing and laboratory processes more effective and efficient. Depending on the prevailing spirit of the times, these projects have gone by various names – from ‘mechanisation’ to ‘PLC control’ and ‘CNC control’, through to ‘automation’ and, today, ‘digitalisation’.
As part of numerous customer and research projects for the footwear industry, PFI has developed, amongst other things, CNC punching machines, automatic sewing machines with tangential fabric guidance and clamp-free latex spray nozzles. A current focus is on laboratory automation.
Furthermore, PFI works with industrial customers to implement automation solutions even outside the footwear industry. For example, complete production lines for heating circuit distribution systems have been implemented, whilst individual process steps – such as the automatic welding of screens onto valve bodies – have been integrated into bespoke machines.
We are happy to support our customers flexibly in the development of tailored automation solutions, tailored to their specific requirements and tasks. Depending on the project, funding – for example through the ZIM programme run by the Federal Government, for funding.
Discover our research projects in the field of automation technology.
Your Contact Person:
Peter Schultheis
Engineering
R&D in the field of biomechanics
Our research area Biomechanics is dedicated to the experimental and analytical study of human movement and the interaction between the body, technical aids and the environment. In our institute’s own biomechanics laboratory , our experts in the fields of sports medicine technology and biomechanics carry out comprehensive analyses of the functional relationships between the foot, movement and footwear. This includes comparative studies of different shoe models with regard to standing and walking stability, pressure distribution and movement characteristics similar to those experienced when barefoot. In addition, we record a wide range of movement aspects of the entire body and develop innovative concepts for the objective assessment of movement quality.
A key focus is on the development and testing of new measurement systems and demonstrators – such as prototypes of ergometers or fitness mats – which use cost-effective sensor technology to detect potentially unfavourable movement patterns and postures. This enables data-driven assessment of rehabilitation processes, training programmes and exercise profiles. The analysis is carried out using AI to automatically identify patterns and establish precise feedback systems.
Whether industrial commissions or non-profit research projects: the use of state-of-the-art measurement technology is an integral part of our biomechanical work. Our range of methods includes, amongst other things:
- Pedobarography using a pressure measurement plate, in-shoe pressure measurement and an instrumented treadmill
- 2D/3D motion analysis for the reconstruction of joint angles and movement sequences
- Electromyography (surface EMG) for measuring muscle activity
- Gait analysis using inertial sensors (IMUs)
- Manual and digital foot measurement (blueprint, 3D scan)
- Development of bespoke measurement systems that are not commercially available
As part of our seminar "Anatomy & Biomechanics – Understanding Gait", erhalten Teilnehmende einen praxisnahen Einblick in biomechanische Messverfahren. Durch die direkte Arbeit an unseren Systemen lernen sie, Bewegungsdaten zu erheben, zu interpretieren und hinsichtlich funktioneller Fragestellungen zu bewerten.
Discover our research projects in the field of biomechanics.
Your Contact Person:
Dr. Tatjana Hubel
ISC – Training and Research
R&D in the field of biotechnology
Climate change, as well as the increasing scarcity and rising cost of fossil fuels: these challenges call for greater use of renewable raw materials and available residual biomass for material and energy purposes. Intensive research and development in the field of biomass utilisation lays the foundations for the efficient and cost-effective use of these resources.
With an interdisciplinary team consisting of biotechnologists, microbiologists, chemists and engineers, PFI-Biotechnology focuses its research activities on the following areas, amongst others:
Biogas / Power2Gas
Optimising process biology still offers considerable potential for further efficiency gains in biogas production. Our aim is to shed light on the complex interactions between microbial groups in the biogas process and to gain a deeper understanding of the optimal growth and nutrient conditions. In addition, we are investigating the effects of trace elements, enzymes and other additives on the biogas process. We are also investigating waste fractions that have been little used to date to assess their suitability as substrates for biogas production. Finally, we are developing new process engineering approaches as well as innovative reactor technology in the field of the biological methanisation of green hydrogen and CO2.
Fermentation / Biopolymers
The use of organic residues as feedstock for bio-based chemical and polymer production is set to become increasingly important in the future. We develop and optimise innovative fermentation processes to enable the increased production of platform chemicals from residual and waste fractions derived from food production and agriculture. At the same time, we are working on the isolation and characterisation of particularly high-performance and robust new production organisms. The use of residues presents particular challenges in the field of fermentation for both upstream and downstream processes. Here, in collaboration with partners from industry and academia, we are developing new approaches to the pre-treatment of biomass and the purification of fermentation solutions.
Discover our research projects in the field of biotechnology.
Your Contact Person:
Dr. Stefan Dröge
Biotechnology
Research in the field of biorefinery technology
The research area focusing on biorefinery technology is concerned with utilising renewable raw materials as a sustainable source of carbon. The aim is to extract basic chemical building blocks from these materials for the production of energy sources and everyday products – as an environmentally friendly alternative to petroleum-based feedstocks.
The processes developed in basic biotechnology research (e.g. fermentation) are combined with environmentally friendly chemical and physical processes (e.g. hydrothermal digestion) and designed and implemented as practical plants by an interdisciplinary team of engineers, technicians and skilled workers.
The following plants have been implemented on an industrial scale in recent years:
Thermal-energy-optimised multifunctional reactor for biogas fermentation
Since 2014, a multi-chamber fermentation plant has been in operation at the Pirmasens Energy Park, which incorporates the processes of hydrolysis, biogasfermentation, hygienisation, and the storage of substrate and fermentation residues. In future, this plant is set to implement various fermentation processes for biopolymer production, enabling the gradual material and energy recovery from the biomass used.
Power-to-Gas (P2G) via biological methanisation of hydrogen produced by electrolysis
In 2017, a P2G plant comprising two reactor columns (1.5 m diameter × 25 m high) was commissioned at the Pirmasens Energy Park; this plant is capable of producing up to 50 Nm3/h of methane from biogas, CO2 and hydrogen. Following the expansion of this plant to include a water electrolysis facility (2 MW, 400 Nm3/h), from 2029 onwards, electrical energy from a ground-mounted PV system is to be used for the production and long-term storage of 100 Nm3/h of methane for injection into the natural gas grid.
Recovery of plant nutrients at sewage treatment works
At the Felsalbe sewage treatment works in Pirmasens, a nutrient recovery plant (NRA) has been installed, which enables ammonium nitrogen and ortho-phosphorus to be converted into magnesium ammonium phosphate (MAP). In particular, phosphorus – a limited resource – can be recovered in this way as a pollutant-free fertiliser for agriculture. With some modifications, this process could also be used in future for the recovery of phosphorus from incineration residues.
Discover our research projects in the field of biorefinery technology.
Your Contact Person:
Benjamin Pacan
Research Facilities
R&D in the field of testing technology
The name Testing and Research Institute already encapsulates what we stand for: testing and research. We put ‘testing’ into practice not only through chemical and physical material testing, but also through the development of new, innovative testing methods and modern testing facilities.
The PFI has an extensive portfolio of test equipment and testing machines for physical testing of footwear and footwear components, the majority of which are developed and manufactured in-house. Numerous standardised test methods – including those relating to safety footwear – were co-developed by the PFI. The test equipment from the comprehensive catalogue of test equipment is used in the in-house laboratories and is continuously adapted to new requirements, further developed and optimised.
Furthermore, PFI has already developed over a hundred test devices, test machines and test benches tailored to the specific needs of industrial customers – from the initial concept through to design and control system planning right through to commissioning. We offer the full range of services from a single source.
We look forward to close collaboration with our customers and to exciting, innovative projects that help to objectively and reliably assess product quality – not just of shoes – using state-of-the-art testing technology .
Wir freuen uns auf den engen Austausch mit unseren Kunden und auf spannende, innovative Projekte, die dazu beitragen, die Produktqualität – nicht nur von Schuhen – mithilfe optimaler Prüftechnik objektiv und zuverlässig zu beurteilen.
Discover our research projects in the field of testing technology.
Your Contact Person:
Peter Schultheis
Engineering
R&D in the field of footwear technology
Footwear and leather are among the PFI’s core areas of expertise. With over 70 years’ experience, the Footwear Technology research division combines scientific research, technical development and practical application. It encompasses both the development of new footwear concepts and technological innovations and optimisation approaches for materials, designs, manufacturing processes, comfort, safety and sustainability.
The focus is on holistic solutions for the footwear industry. The footwear technology at PFI supports the entire value chain – from the initial idea through design, material selection and prototyping right through to development ready for series production. It combines insights from materials science, biomechanics, manufacturing technology, digitalisation and quality assurance to develop high-performance, durable and sustainable products.
Services range from design and trend research, through design drawings and renderings, to the selection of suitable materials and technologies. Digital tools such as Rhino 3D, Jevero and Procam: Dimensions are used in upper and sole development. This is complemented by 3D scanning, CAD modelling and rapid prototyping using 3D printing.
An in-house manufacturing facility enables rapid prototyping, allowing concepts to be implemented, tested and optimised iteratively. In the PFI laboratories, materials are analysed physically and chemically to ensure quality, functionality and durability. Particular emphasis is placed on sustainable materials, resource-efficient processes and circular product strategies.
Current research activities centre on the development and evaluation of various footwear concepts, with a focus on functionality, biomechanics and material performance. Research is also being carried out into the optimisation of protective and safety footwear, the slip resistance of soles and floor coverings, and methods for cleaning and sanitising footwear. Optimising comfort is also a key priority, particularly in terms of the interplay between design, fit and material properties.
The PFI is also involved in a wide range of research activities in the field of quality assurance. On the one hand, this involves the research and development of new and optimised standard test methods and machines; on the other hand, it also covers customer-specific testing tasks.
Another key focus is on modern manufacturing technologies in the context of Industry 5.0, which integrate digital development methods, prototyping and flexible production processes. In addition, aspects of recycling and the circular economy are taken into account in order to close material loops, use resources more efficiently and promote sustainable product life cycles.
In addition, research is being carried out into solutions for outpatient rehabilitation, with the aim of supporting the mobility, safety and quality of life of user groups with varying needs. The focus is always on combining innovative materials, technical feasibility and practical application.
Discover our research projects in the field of footwear technology.
Your Contact Person:
Liselotte Vijselaar
ISC – International Shoe Competence Center
R&D in the field of the circular economy and material flow management
A sustainable circular economy views resources not as waste, but as valuable material flows. This is precisely where our research area ‘Circular Economy and Material Flow Management’ comes in: we analyse, design and optimise material and energy flows holistically – from the initial product concept through to technical implementation in processes and plant.
As part of application-oriented research projects – often in close collaboration with industry partners – we develop solutions for both technical and biogenic material flows. In the product sector, the focus is on plastics and complex multi-component products such as shoes. By combining ‘Design for Recycling’ and ‘Design for Circularity’ with targeted material optimisation and the systematic identification of end-of-life scenarios, we lay the foundations for durable, repairable and highly recyclable products. At the same time, we research and design recovery pathways for biogenic waste materials such as organic waste and food scraps – from separate collection and material flow analyses through to recycling, digestion and biogas processes, including logistics, administration and plant design.
Our work combines R-strategies, material and product optimisation, and the planning and implementation of technical systems. Working in close collaboration with the fields of biotechnology and footwear technology, we develop practical solutions – from research and development right through to prototyping. On the following pages, you will find our current and completed projects.
Discover our research projects in the field of the circular economy and material flow management.
Your Contacts:
Dr Svenja Dill
Research Facilities
Christian Schadewell
Research Facilities
R&D in the field of training and further education
At PFI, we develop and implement a wide range of training and continuing professional development projects based on European cooperation and innovative learning concepts. A key focus is on Erasmus+ projects and cross-border partnerships, in which we work together with international universities, research institutes and companies to design forward-looking educational programmes for the TCLF sector (textiles, clothing, leather and footwear).
These EU-funded collaborations facilitate the development of strong networks, structured knowledge exchange and the joint development of strategies to strengthen competitiveness in Europe. A key component is the creation of high-quality training materials, digital modules and practical teaching formats. In addition, we utilise modern digital learning environments such as e-learning platforms, virtual training rooms, virtual campus concepts and AR/VR and metaverse applications, which support realistic, flexible and interactive learning processes.
The findings from the projects are incorporated directly into our own seminars, enriching them with new teaching approaches, technologies and content. At the same time, the projects offer students, trainees and company employees the opportunity to take part in EU-wide competitions and international exchange activities, thereby gaining valuable experience within a European network.
Companies can be actively involved in the projects – for example, by providing real-world case studies, pilot applications or feedback processes – and subsequently benefit from freely available materials such as curricula, guidelines, digital tools and training resources.
Discover our research projects relating to training and further education.
Your Contact Person:
Dr. Tatjana Hubel
ISC –Training and Research