Discover how Ryan Dhindsa, Managing Director at Tuffking, is leading the charge in pioneering new technology for firefighter footwear
Founded in 1854 as Giffard Newton & Sons, the Tuffking brand is the oldest fire boot manufacturer globally, and is experiencing a significant phase of expansion. The company’s leading brand Tuffking is preparing for a 40% increase in turnover this year, largely driven by its focus on developing firefighting gear.
Tuffking recently embarked on a journey of innovation, leveraging its 170 years of technical expertise to modernise its entire product range. This innovation led to the creation of a pioneering new era of fire-fighting footwear that will protect modern day fire fighters.
These boots are notably lighter and more sustainable than their predecessors and contain no harmful chemicals such as lead, chromium or PFAS which can often be found in fire-fighting protective equipment.
The innovative new range by Tuffking has been designed to meet the rigorous demands of modern firefighting professionals.
We spoke to Dhindsa, Managing Director at Tuffking to find out more about the company’s plans to revolutionise the firefighting boot industry.
Could you introduce yourself and explain your role at Tuffking?
My role as Managing Director is to put Tuffking back on the map as the leading firefighting boot manufacturer globally. We have a long history of manufacturing safety boots, military boots and firefighting boots for the UK Government, dating back to World Wars I and II.
Tuffking was the first company globally to manufacture a leather firefighting boot to safety standards, making us pioneers in the industry. My goal is to restore our position as the leading firefighting boot manufacturer and have British innovation lead the global charge in safety.
Our boots have always been known for quality, even when they were not traditionally the most attractive looking. We’ve maintained the best quality record in the industry with 0.71% return rate over 10 years, with firefighters often referring to our boots as tanks because of their durability.
Firefighters have told me they still use their boots after 15 years of service. We want to continue this reputation while also innovating.
Could you share insights into the research and development process to developing Tuffking’s new footwear?
When I joined this organisation, I travelled across the country, from Cornwall, UK to Inverness, Scotland, to meet with various fire departments and emergency service personnel to understand their needs.
These people are heroes, putting their lives on the line every day, so we have a responsibility to make the best kit possible. Meeting the firefighters and understanding their varying requirements was the most inspiring part, acting as the catalyst for our new range.
The needs change from region to region. For instance, the footwear needed in Devon and Somerset might differ due to geographical terrain and weather conditions compared to North Yorkshire.
Traditionally, it has been a one-size-fits-all approach where everyone gets the same boots. However, I’ve learned it’s multifaceted and they require footwear adequate for their terrain.
There are also gender differences to consider, as I discovered through my work on the National Committee for firefighters’ PPE. Ensuring there are options for female firefighters is crucial.
Can you describe the common issues that firefighters face with their current footwear?
Traditionally, firefighting boots have always used steel toe caps and steel midsoles. The midsole is the part that goes under the foot to protect against nails penetrating the bottom of the wearer’s foot.
Stainless steel is very strong and durable. But the problem with steel is that it doesn’t cover the entire surface area of the boot. It doesn’t go all the way to the edges because steel, being metal, is very rigid. If you put it all the way to the edges of the outsole, it could start to protrude and cause cracking.
The advantage of using a composite or Kevlar midsole, which we use in general safety footwear, is that you get surface area protection all the way to the edges of the boot. So, you get a little more surface area in penetration resistance.
At Tuffking, we try to find these gaps in the market and innovate because we have more boot making experience than anyone else in this field. We can move very fast because we have excellent relationships with our raw material suppliers.
How was the material tested to ensure it meets the rigorous demands of firefighting?
We realised that people want to move away from steel towards composite. The problem is that penetration resistance testing is done at room temperature. However, firefighters run into burning buildings, so the testing method needs to reflect that.
Steel is protective and will pass the test if using high-strength non-corrosive stainless steel for hot nail penetration. Unfortunately, there have been issues of hot nails penetrating firefighters’ feet in the UK and other countries. Traditional Kevlar used for penetration resistance is not tested at high temperatures.
We needed to develop a test method, so we created a chamber with a testing house to heat the nail up to 250 degrees Celsius.
First and foremost, we needed a test method. The second obstacle was developing a material that could withstand high temperatures.
You might ask: if steel passes the test, why not use steel? The problem is that firefighters can walk over live electrical wires and steel weighs more.
This is more flexible and lightweight, which is important from a health and safety perspective. Conductive materials like steel in footwear pose risks when walking over live wires.
Firefighters want composite, but it doesn’t pass high-temperature tests. So, we developed a testing device and then worked on creating a composite material that can withstand hot temperatures.
We collaborated with raw material suppliers worldwide, examining different techniques and percentages used in Kevlar midsoles.
Manufacturing techniques vary in South America, Europe and the Far East. We looked at the different percentages of materials used and how we could infuse something to help penetration at high temperatures.
Another factor was the thickness. Traditional midsoles are about 3 to 3.5 millimetres thick. Making them thicker might seem like a solution, but it affects fitting, slip resistance and the stride of the boot.
Were we to simply increase the thickness to 5 millimetres, the boot would be taller, impacting fitting and wearability.
How did you overcome these challenges?
We wanted to infuse raw material to help penetration at high temperatures without affecting the boot’s structure. We explored para-aramid fabric, used in firefighting suits.
These suits are expensive and difficult to make so we reached out to fabric manufacturers to understand how para-aramid fabric is made and if it could be infused with Kevlar.
We spent over three years testing different concentrations and percentages to ensure durability and avoid cracking. Nonstop testing in the lab was necessary to make sure the material was feasible before incorporating it into a boot.
After almost three years, we found the right concentration and thickness. We then tested the material inside the boots. Today, we’ve successfully achieved our goal. We’ve made this material and we are the only firefighting boot manufacturer in the world to use it.
What are the key features of this new material?
Our new boots are lighter, fully composite and contain no metal. They pass tests up to 250 degrees Celsius.
To give context, the firefighting standard EN 15090:2012 requires the outsole to withstand a 250-degree Celsius plate for 45 minutes. This isn’t an arbitrary temperature; it’s uniform with the current test method.
We wanted our boots to withstand and exceed real-life challenges of fire fighters. Generally heat resistance testing for footwear is conducted between 250 C to 300 C so we were able to stay in-line with the industry standard for temperature.
Our new material combines the strength and durability of steel with the flexibility and lightweight properties of composite materials.
It provides complete surface area protection and withstands high temperatures, addressing the critical issue of hot nail penetration.
The material also eliminates the risks associated with steel, such as conductivity and weight, making it safer for firefighters who may encounter live electrical wires.
Looking forward, how does Tuffking see this technology developing?
We believe this innovation will significantly improve firefighter safety and performance. Our boots now offer better protection, comfort and durability, meeting the demanding conditions firefighters face daily.
This project has been a significant investment in time and resources, but the results have been worth it. We have successfully created and implemented this unique material in our firefighting boots, making us the only company in the world to use it.