Toe-Puffs & Counters Solutions

INTELON
Toe-Puffs & Counters

Extruded semi-rigid material with the unique "ping-pong" memory effect engineered for shoe toe-puffs and counters with PU adhesive and dual backer construction for superior bonding and structural performance.

130–150°C
Press Temperature
6–12 sec
Contact Time
≥100°C
Min Interface Temp
TMS1+2
Two Grades Available
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Product

Engineered for
shape & structural memory

Extruded Ni/PU composite with the signature "ping-pong" elastic memory — ensuring toe boxes and heel counters snap back to shape after compression, maintaining the shoe's form over its full lifecycle.

INTELON is a semi-rigid extruded material purpose-built for toe-puff and counter applications in footwear manufacturing. It features a PU adhesive system with two backers for reliable bonding to uppers under heat and pressure. Available in TMS1 and TMS2 grades across five thickness profiles from 0.50 mm up to 1.30 mm to suit lightweight athletic and heavy-duty safety footwear alike.

Ping-Pong Memory Effect PU Adhesive Dual Backer Semi-Rigid TMS1 & TMS2 Grades 5 Thickness Profiles
Shoe Manufacturing
Extruded INTELON Sheet
Semi-rigid with PU adhesive & dual backer
130–150
Press Temperature (°C)
0.50 – 1.30 mm
Thickness Range (all grades)
6 – 12 sec
Recommended Contact Time
≥100°C
Min. Interface Temperature
Footwear Production
Precision Toe-Puff Shaping
Pneumatic press with heated curved plate
Counter Assembly
Counter Application
Bonds directly to upper material
Why Choose It

Six reasons cobblers
specify INTELON

All grades tested in production footwear environments. INTELON's extruded construction delivers consistent thickness, reliable adhesion, and shape recovery proven across athletic, fashion, and safety footwear production lines.
"Ping-Pong" Memory Effect
INTELON's extruded construction provides elastic shape memory the toe-puff and counter return to their original profile after compression, maintaining the shoe's silhouette and structural integrity throughout its life.
PU Adhesive with Dual Backer
The built-in polyurethane adhesive system, protected by two backers, activates cleanly under heat press conditions eliminating separate glue steps and ensuring consistent, peel-resistant bonding to the upper material.
Semi-Rigid Structural Support
Strikes the ideal balance between flexibility and rigidity enough stiffness to hold the toe box shape under wear stress, yet flexible enough to be formed over a last without cracking or delamination during lasting.
Fast Cycle Times
6 to 12 second contact time at 130–150°C makes INTELON well-suited for high-volume production lines the short dwell time minimises press cycle duration without sacrificing bond quality or shape definition.
Two Grades — Five Thicknesses
TMS1 and TMS2 grades cover five thickness profiles from 0.50 mm to 1.30 mm, giving design engineers the range to specify the right stiffness level for lightweight sneakers through to heavy-duty safety footwear.
No Binding Lasting Period
Unlike solvent-activated stiffeners, INTELON has no binding time constraint after application the bonded component can proceed immediately to lasting, stitching, or further assembly without waiting for a cure window.
Construction

How INTELON is built

01
Extruded Base Layer
A semi-rigid thermoplastic compound is extruded to a uniform sheet, creating the core structural layer that provides the characteristic "ping-pong" elastic memory and dimensional stability required in toe-puff and counter applications.
02
PU Adhesive Coating
Polyurethane adhesive is applied in a controlled coating process to one face of the extruded sheet. The PU system is formulated to activate cleanly at 130–150°C, delivering a peel-resistant bond to a wide range of upper materials leather, synthetic, and textile.
03
Dual Backer Lamination
Two backer layers are laminated over the adhesive face protecting the PU surface during storage, die-cutting, and handling, and preventing blocking in roll or sheet form. Backers are stripped just before application in the press.
04
Slitting & Sheet Cutting
Finished INTELON is slit or cut to your specified dimensions supplied in sheet or roll form ready for die-cutting into toe-puff and counter patterns. Both TMS1 and TMS2 grades are available across five standard thickness ranges from 0.50 mm to 1.30 mm.
INTELON Manufacturing
INTELON at a Glance
TMS1+2
Grades
5 SKUs
Thicknesses
PU
Adhesive
2× Bkr
Backers
Technical Data

Product Specifications

All thickness values have a natural variation of ±0.05 mm. Select grade based on required stiffness and upper material characteristics.
INTELON — TMS1 Grade
INTELON Grade Thickness* (mm) Tolerance Grade
472 – TMS1 0.50 – 0.60 ± 0.05 mm TMS1
473 – TMS1 0.55 – 0.65 ± 0.05 mm TMS1
475 – TMS1 0.65 – 0.75 ± 0.05 mm TMS1
477 – TMS1 0.85 – 0.95 ± 0.05 mm TMS1
479 – TMS1 1.10 – 1.20 ± 0.05 mm TMS1
INTELON — TMS2 Grade
INTELON Grade Thickness* (mm) Tolerance Grade
473 – TMS2 0.65 – 0.75 ± 0.05 mm TMS2
475 – TMS2 0.75 – 0.85 ± 0.05 mm TMS2
477 – TMS2 0.95 – 1.05 ± 0.05 mm TMS2
479 – TMS2 1.20 – 1.30 ± 0.05 mm TMS2
PU Adhesive Backed
Dual Backer Construction
Ping-Pong Memory Effect
Make in India
Use Cases

Where INTELON
performs best

INTELON is the preferred toe-puff and counter stiffener when structural integrity, shape memory, and reliable in-line bonding are all required used across athletic, fashion, and occupational footwear production.
Athletic Footwear
Athletic & Sports Footwear
Used in running shoes, trainers, and cleats where the toe-puff must resist repeated flex and impact while snapping back to shape INTELON's memory effect is critical for long-lasting performance.
Safety Footwear
Safety & Industrial Boots
Thicker TMS2 grades (0.95–1.30 mm) provide the structural rigidity needed behind steel or composite toe caps in safety footwear.
Fashion & Dress Shoes
Thinner TMS1 profiles (0.50–0.65 mm) deliver a clean silhouette in slim dress footwear without adding bulk.
↗
Children's Footwear
Lightweight TMS1 grades maintain shape in children's shoes through high-activity wear cycles without stiffness fatigue.
↗
Heel Counter Applications
Applied at the heel counter to provide lateral stability and maintain the back-of-shoe form after repeated pull-on use.
↗
Processing Guide

Instructions of use

Press Temperature
130°C – 150°C
Heated curved plate — adjust to upper material thickness
Contact Time
6 – 12 seconds
Longer dwell for thicker articles (477, 479 grades)
Min. Interface Temperature
≥ 100°C
Minimum effective temperature at upper–INTELON interface

The toe puff is applied using a special pneumatic pressing machine equipped with a heated curved plate, timer, and thermostat. The curved plate conforms the INTELON to the last profile while the heat activates the PU adhesive.

Working conditions should be set to a press temperature between 130°C and 150°C. Contact time ranges from 6 to 12 seconds, increasing with the thickness of the article being processed. The effective interface temperature at the bond line must reach a minimum of 100°C to achieve full adhesive activation.

We recommend carrying out a preliminary bonding test before full production, as application conditions may vary depending on the characteristics of the upper material — particularly its thickness, surface texture, and thermal conductivity.

There is no binding time or constraint on the lasting period after application bonded components can proceed directly to the next production step.

⚠ ATTENTION: Application using a solvent-based glue can chemically affect the PU adhesive present on the INTELON sheet, causing detachment or bond failure. Do not use solvent glue in combination with INTELON. If alternative adhesive systems are required, contact us for technical guidance.
FAQ

Common questions answered

Shoe
What is the difference between TMS1 and TMS2 grades?
+
TMS1 and TMS2 refer to different stiffness formulations TMS2 provides a higher degree of rigidity compared to TMS1 at equivalent thickness. This means TMS2 is better suited to safety and occupational footwear where structural support is critical, while TMS1 is preferred in athletic and fashion footwear where some flex is desirable.
Which grade and thickness should I use for running shoes vs. safety boots?
+
For running and athletic footwear, TMS1 in the 472–475 range (0.50–0.75 mm) provides the right balance of lightweight support and flex. For safety boots, TMS2 grades 477–479 (0.95–1.30 mm) deliver the greater structural rigidity needed to back steel or composite toe caps under impact loads.
Can INTELON be used with solvent-based glues or cements?
+
No. Solvent-based adhesives can chemically attack the PU adhesive coating on INTELON, causing delamination or bond failure. INTELON is designed for heat-press activation only. If you require an alternative bonding method for your line, please contact our technical team for guidance.
Is there a waiting period after pressing before lasting?
+
No. INTELON has no binding time after application there is no constraint on the lasting period, and bonded components can proceed directly to lasting, stitching, or further assembly without a cure window. This is a significant advantage for high-volume production lines.
Can INTELON be die-cut to custom toe-puff and counter patterns?
+
Yes. INTELON is supplied in sheet or slit-roll form ready for die-cutting on standard clicking presses. The dual backer protects the adhesive face during cutting. Please share your pattern specifications and required thickness with us when placing an order.

Ready to build
better footwear?

Custom thickness profiles, TMS1 and TMS2 grades, slit rolls or die-cut blanks all available on request. Our team will help you select the right INTELON specification for your upper material and production process.

PU Adhesive Backed
Ping-Pong Memory
Custom Die-Cut Available
Make in India
Premnath +91 90808 72036
Hariharan +91 83444 56565
ragothaman@gold-chamois-925398.hostingersite.com
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