How uvex overhauled safety footwear for 700 engineers
By replacing uncomfortable, short-lived footwear with high-performance, well-fitted alternatives, uvex and distribution partner Howcroft helped a national retailer resolve ongoing foot health issues and improve working conditions for 700 maintenance engineers.
Background
A leading UK retailer operates large-scale warehouse and distribution facilities to support its extensive store network and online operations. The company’s 700 maintenance engineers are responsible for keeping automated machinery, production lines, and handling systems running smoothly across multiple sites.
The role is physically demanding, with engineers covering up to 40,000 steps during 12-hour shifts. Tasks range from repairing top rails and climbing ladders to working at elevated heights in varied warehouse environments.
Appropriate footwear that offers comfort, durability, and support should therefore be non-negotiable. Yet, the retailer had been struggling to find a solution that met these needs over the long term.
Identifying the problem
The company had switched between several footwear suppliers over recent years, moving away from uvex in favour of brands offering cost savings. However, the lower-cost alternatives led to recurring issues:
- Discomfort: Hard soles, poor shock absorption, and insufficient impact protection.
- Health concerns: Increased reports of pinching, blisters, skin irritation, and foot pain.
- Durability problems: Footwear was wearing out quickly, leading to frequent replacements.
The footwear from one brand in particular which retailed at around £80 - 85 per pair proved expensive due to high turnover. Over 11 months, the replacement rate was estimated at around 1,000 pairs.
The solution
Introduced through distribution partner Howcroft, a uvex expert visited the retailer to present a tailored footwear programme.
Key elements included:
- Precision fitting
On-site sizing sessions with arch support insoles to ensure correct fit for every engineer. - Product selection
Three uvex 1 G2 models were chosen - lace-up boot S3 (68392), shoe (68382), and trainer (68342) - for their comfort, support and build quality. - Breathability
Footwear designed to keep feet cool and dry, reducing the risk of fungal infections. - Longevity
Engineers reported that previous uvex models had lasted up to four years in service. - Footwear care education
Guidance on insole rotation, washing, and drying to maintain comfort, hygiene, and performance. Spare insole sets were issued with each pair.
Although an S3 safety rating was not strictly required for the role, the company opted for this higher level of protection. The quality of the footwear and the engineers’ positive response meant the company committed to fitting all 700 staff without a trial phase.
Results
- Improved comfort:
Engineers reported less fatigue, reduced skin issues, and no pinching or blistering. - Lower replacement rates:
More durable footwear reduced turnover, offsetting higher initial purchase costs. - PPE engagement:
Staff welcomed the fitting process and care guidance, increasing buy-in and consistent use. - Operational readiness:
Engineers could work full shifts without discomfort, supporting productivity and safety.
Conclusion
By addressing fit, comfort, and durability together, uvex and Howcroft delivered a long-term footwear solution and cost savings that met the demands of a large, mobile maintenance workforce. The initiative reduced health complaints, cut waste, and re-established a consistent PPE standard across multiple sites.
