Water Saving Technology in Textile

1. Water Saving Technology in Textile

2. Meaning of W.S.T W.S.T means Water Saving Technology. It is a new concept which we have implemented the complexity from the Fiber & Yarn to the RMG (ready made garments). - No investment is required for this Technology - This technology is documented by significant reduction of water, power, CO2, & also the cost. - It will also meet the environmental compliances for the industries.

3. Fiber & Yarn: The fiber & yarn should be selected under such condition of using no enzyme wash, which is harmful for the workers & the environment as well. Highlights of using Low TPI yarn: (17.5-19) Advantage of Low TPI from fiber to RMG: ● Stand by time of needles & sinkers at least 10- 15% through the softness of yarn ● Pick up rate (Exhaustion rate) of chemicals & dyes in fabric increases 15%. That means we are saving this amount. ● Fabric is coming super soft with less softener. ● Because of super soft fabric, no chance for needle holes doing sewing.

4. ● The fastness is becoming half grade better. ● Last but not the least we are avoiding the spirality of the RMG. Highlight of using compacted yarn: we can avoid enzyme during less hairiness. Highlights of using Carded & Combed yarn: Through singeing we can avoid the hairiness , but hand feel is not significant CVC Yarn: ● CVC has the same criteria like 100% cotton. ● In general there is 2 types of blended cotton with polyester 1. CVC contains disperse dye able polyester 2. CVC also contains cationic dye able polyester

5. Information collected by Water Ambassadors: Utility & services: Sl No. Machine Name Brand Origin Model Capacity No of Machine 1 Boiler Cochran Scotland S23 7000 1 2 Boiler Cochran Scotland SKF20 10000 1 3 Air Compressor Boge Germany S40792 4000 cu.m/hr 3 4 Air Compressor Atlas Copco Belgium SKF20 4m3/hr 2 5 Diesel Generator Musgrove USA HC540 500 KVA 1 6 Diesel Generator Perkins USA HC646 720 KVA 1 7 GAS Generator Catterpiller USA M3516 1020 kw 1 8 GAS Generator Catterpiller USA 1174 kw 1 9 ETP Bio Chemical India N/A 150m3/w 1 (**** Data from Landmark website)

6. Number of Dyeing machine for Bulk Production Capacity (in Kg) Sl No Name/ Brand Origin Liquor Ratio M/C Feature 1 2 3 4 5 6 7 8 9 Thies Thies Thies Thies Thies Thies Thies Fongs Fongs Fongs Fongs Germany Germany Germany Germany Germany Germany Germany China China China China Number of Sample dyeing Machine 150 300 450 450 800 800 1200 600 800 800 1500 1:6 1:6 1:6 1:6 1:6 1:6 1:6 1:8 1:8 1:8 1:8 JET JET JET JET JET JET JET JET JET JET JET 10 11 Capacity (in Kg) Sl No. Name/ Brand Origin Liquor Ratio M/C Feature 1 2 3 4 Thies Thies Santex Santex Germany Germany Switzerland Switzerland 15 60 40 40 1:6 1:6 1:6 1:6 S/ JET S/ JET S/ JET S/ JET

7. Machine of Finishing Section Sl No. M/C Name Brand Origin Capacity (Ton/day) 7 1 Open Compactor Bruckner Germany 6-7 2 Tube Compactor Sperttorumar 8 3 Stanter Bruckner Germany 10 4 Stanter Alkan Turkey 10 5 Spliting Bainco Italy 8 6 Dewatering Santex Switzerland 8 7 Dryer Santex Switzerland 7-8 8 Swiding M/C Lafar Italy 6 9 Back Swing

8.  No. of Labor working in Dyeing to Finishing Section: Dying Section- 88 (3 shift) Lab Section- 12 (3 shift) Quality Control Section- 12 (3 shift) Finishing Section- 81 (3 shift) Existing Total Dyes & chemical consumption for 15 tons Knit fabric/day for dyeing Dyes 1347 Kg/day Salt-8640 Kg/day Soda Ash-2160 Kg/day Water-1080000 Lts/day How much water we can save by using Solophenyl Dyes: Water saving for 15 ton Fabric in Landmark: In existing Reactive dyeing process required water is 1351500 ltr In solophenyl dyeing process required water is 402000 ltr So we are saving 949500 ltr water per day.

9. Below is the graph of Classic Reactive Dye: (In international Std. Time & water needed in RD 7-8 hrs, & 70-80 ltrs but in Bangladesh time & water needed in RD 8-9 hrs, & 90-100 ltrs)

10.  Lab Dip report of R.D Dark Blue (100%Cotton) (1.5% shade) G.S.M- 145 1. Dimensional Stability to washing (Machine wash at 40c) After the 1stwash Length (%) 5.5 % Width (%) 1% 2. Color fastness to washing (30 minutes wash at 40c in 0.4% detergent) Color Change : Color staining: Acetate: 5 Cotton: 4-5 Nylon : 5 Polyester: 5 Acrylic: 5 Wool: 5 Requirement 5% 4 4-5

11. 3. Color fastness to rubbing (I.S.O. 105x12-1993) Dry: Wet: 4. Spiral: 5. Pilling test: 6. Exhaustion Rate: 3 2-3 5 4-5 65%

12. • Below is the Curve of Solophenyl Dyes: 1 Batch Dyeing (International Std. Time & water needed 3-4 hrs, & 30-40 ltrs & in our trial we met the international standard)

13.  Lab Dip report of S.D Black (100%Cotton) (4% shade) (2 Batch dyeing) G.S.M- 150 1. Dimensional Stability to washing (Machine wash at 40c) After the 1stwash Length (%) 5.5 % Width (%) 1% 2. Color fastness to washing (30 minutes wash at 40c in 0.4% detergent) Color Change : Color staining: 4 Cotton: 4-5 Nylon : 4 Polyester: 4-5 Acrylic: 4 Wool: 4 Requirement 5% 4 -5 4-5 Acetate:

14. 3. Color fastness to rubbing (I.S.O. 105x12-1993) Dry: Wet: 4. Pilling test: 5. Exhaustion Rate: 4-5 3-4 4-5 90%

15. Difference between classic reactive & Solophenyl/Avitera Dyes Item Reactive dyes Solophenyl/ Avitara dyes 1. Process time 8-10 hours/ batch 4-6 hours/ batch 2. Bath 10-12 / Batch 3-4/ batch 3. Water Consumption 94 ltr/ KG 28 ltr/ KG 4. Exhaustion Rate 60-70% 85-99% 5. Process Loss 10% 6-7%

16. Cost comparison of Classic Reactive & Solophenyl Dyes (LM) Material 100% cotton Yarn Count 30’ S Color Blue Item Dyes Gluber Salt Enzym Classic Reactive Solophenyl Savings 2.5% 1.5% 25% 1.00% 29.50% 100% 54.50% 0.5/ kg 0.00/ kg CO2 Emission 50% Dyeing Cycle Hrs Manpower Cost 10 4 6hrs dyeing cycle 62.50%

17. Fastness Report of Landmark Rubbing fastness Fastness 4 to 5 4 to 5 4 4 to 5 4 4 to 5 4 to 5 4 4 to 5 4 4 to 5 4 to 5 4 4 to 5 4 4 to 5 4 to 5 4 4 to 5 4 Fabric Color Washing Color Fastness 4 to 5 4 4 4 4 4 to 5 4 4 4 4 4 to 5 4 4 4 4 4 to 5 4 4 4 4 Pilling testPerspiration Sl No. Fabric Type Hand feel test 4 to 5 4 4 4 4 4 to 5 4 4 4 4 4 to 5 4 4 4 4 4 to 5 4 4 4 4 Low Twist Yarn Combed with singeing Combed without singeing Carded with singeing Carded without singeing Low Twist Yarn Combed with singeing Combed without singeing Carded with singeing Carded without singeing Low Twist Yarn Combed with singeing Combed without singeing Carded with singeing Carded without singeing Low Twist Yarn Combed with singeing Combed without singeing Carded with singeing Carded without singeing 4 to 5 4 4 4 4 4 to 5 4 4 4 4 4 to 5 4 4 4 4 4 to 5 4 4 4 4 4 Very good Good Medium Medium Medium Very good Good Medium Medium Medium Very good Good Medium Medium Medium Very good Good Medium Medium Medium 4 to 5 4 to 5 4 4 4 4 to 5 4 to 5 4 4 4 4 to 5 4 to 5 4 4 4 4 to 5 4 to 5 4 4 1 Yellow 2 pink 3 Blue 4 Grey

18. W.S.T Roadmap for 100% Cotton*** Dyes Use Year % Water Consumption (ltr/Kg) Time in hours BD 100 Intl' 70 Minimizing 42 BD 10 Intl' 60 Classic Reactive Dye 7 to 8 4 20 New Generation RD 30 6 2012 20 Solophenyl 25 5 4 Total minimization of water if we follow International standard 40 Classic Reactive Dye 53 28 100 70 10 7 to 8 4 30 New Generation RD 30 9 2013 30 Solophenyl 25 7.5 44.5 21 4 Total minimization of water if we follow International standard 30 Classic Reactive Dye 100 70 10 7 to 8 4 40 New Generation RD 30 12 2014 30 Solophenyl 25 7.5 40.5 4 Total minimization of water if we follow International standard *** All this depends on the fashion or on the color

19. Dyeing Proposal 1. For 100% cotton: 1.1) Classic reactive dyeing process, 95% used in BD. – Water consumption 60 – 80 l/kg – Process time 6-8 hours – Exhaustion Rate 60 – 70 % It has to be changed within few years because it is killing Environmental compliance during very bad exhaustion rate & time and water consumption is extremely high. 1.2) New generation reactive dyeing process, Avitera . – Water consumption 30 – 40 l/kg – Process time 3-4 hours – Exhaustion Rate 80 - 90%

20. New generation dyes will replace step by step the classic reactive dyes. Because these are Environmental friendly and has good fastness, require less time and water, & excellent exhaustion rate. 1.3 Solophenyl Dyes – Water consumption 20 – 30 l/kg – Process time 3-4 hours – Exhausting Rate 85 - 99% This kind of Dyes are excellent for light and medium color as well as for black and navy. It has high economical savings and excellent fastness by using fixing agent Albafix E. 1.4 OBD (One Batch Dyeing): It is possible and recommended.

21. Cotton blended with polyester CVC/TC: Classic 2 batch Dyeing (95% used right now) – Water consumption 120 -140 l/kg – Process time 12 -14 hours – Exhausting Rate 60 – 70 % This kind of Dyes has to be replaced very soon, because killing Environmental compliance during very bad exhausting rate, time and water consumingextremely high. Scour Dyeing (SD) Option 1 - Disperse Dye able PE Fiber blended – Water consumption 60 – 80 l/kg – Process time 6-8 hours – Exhausting Rate 60 – 70 % Step 1. Scouring and Polyester Portion by Temperature of 130 C. Step 2. follows classic Reactive Dyeing Process.

22. Option 2 - Cationic Dye able PE Fiber blended – Water consumption 60 – 80 l/kg – Process time 6-8 hours – Exhausting Rate 60 – 70 % Step 1. Scouring and Polyester Portion by Temperature below 100°C Step 2. follows classic Reactive Dyeing Process. Option 3 - Disperse Dye able PE Fiber blended – Water consumption 40 – 60 l/kg – Process time 5 -6 hours – Exhausting Rate 80 -90 % Step 1. Scouring and Polyester Portion by Temperature of 130°C. Step 2. follows new Generation Reactive Dyeing Process (AVITERA).

23. Option 4 - Cationic Dye able PE Fiber blended – Water consumption 40 - 60 l/kg – Process time 5 -6 hours – Exhausting Rate 80 - 90% Step 1. Scouring and Polyester Portion by Temperature below 100 °C. Step 2. follows new Generation Reactive Dyeing Process (AVITERA). 2.3 One batch Dyeing (OBD) Option 1 - Disperse Dye able PE Fiber blended – Water consumption 30 -40 l/kg – Process time 3 - 4hours – Exhausting Rate 86 – 90 % All in one Scouring, Cotton Solophenyl Dyes + Polyester Portion by Temperature of 130° C. High efficiency Process, high fastness in light & medium colors.

24. Option 2 - Cationic Dye able PE Fiber blended – Water consumption 30 – 40 l/kg – Process time 3 - 4 hours – Exhausting Rate 86 – 90 % All in one Scouring, Cotton Solophenyl Dyes and Polyester Portion by Temperature below 100° C. High efficiency Process, high fastness in light , medium and dark Colors.