Conventional denim manufacturing is an ecologically impactful enterprise. Wet processing for dyeing and ending supplies creates massive volumes of wastewater stuffed with dangerous chemical compounds and onerous metals.
In response to this concern, the denim business has largely been targeted on cleansing up the water that’s launched into the atmosphere. But Pakistani producer AGI Denim is taking a unique path to extra successfully decrease the water affect of denims.
“Denim is a dirty manufacturing production area,” stated Ali Tekin, analysis and growth director at AGI Denim. “We are creating a huge amount of wastewater and it is making our earth dirtier, so we need to do something about it.”
AGI’s proprietary Double Zero know-how drastically reduces the quantity of water wanted for each dyeing and ending. Breaking down the numbers, the traditional dyeing course of requires 3.6 liters of water per meter of yarn, whereas Double Zero makes use of simply 0.65 liters for a similar quantity of denim, a discount of 83 %. For ending, the 13 liters of water usually wanted for the method have been changed with simply 0.28 liters per meter, virtually 95 % much less water.
While Double Zero processes scale back the quantity of water consumed, the zero stands for the quantity of wastewater launched. AGI recovers or evaporates all of the water left over on the finish of dyeing and processing, eliminating the potential for any dangerous substances or effluents to be leeched into the atmosphere. Recovered water is recycled for processing, additional decreasing the producer’s water footprint.
Conventional dyeing requires a pre-wash to assist with dye penetration and a post-wash to assist with points resembling fading. AGI engineered the Double Zero course of in order that it may take away these steps and scale back water from dyeing and ending whereas sustaining the identical high quality and magnificence requirements. Double Zero dyed and completed denim has the additional benefit of responding effectively to sustainable lasers.
“Until two or three years ago, people just tried to do sustainability without getting the same quality,” stated Tekin. “But now the end consumer is looking for the same quality level and same looks with a sustainable form. This is a very critical point, so in our Double Zero, we are not sacrificing the quality or the look.”
One facet that improves the sturdiness and efficiency of all of AGI’s indigo denim is using liquid dyestuff, which is extra secure than powder variations.
Double Zero was in growth for greater than six months earlier than launching virtually two years in the past. Originally, the method was restricted to blue denims in various shades, however it has since expanded to black dye in response to consumer demand. “We got so many reactions and feedback from the customer side, and they wanted us to enlarge all of our production line,” stated Tekin.
AGI goals to have Double Zero cowl about 90 to 95 % of its manufacturing line within the close to future.
While AGI doesn’t promote immediately to finish shoppers, it’s pondering of the advertising alternatives for retail manufacturers. To again up its work on Double Zero, the mill introduced in auditors from SGS to report on its water affect.
“If I don’t have any data, it will not be easy to explain to the customer,” stated Tekin. “And the customer has to explain also to the end consumer. So now we are also servicing our customer with some reports and certification.”
The want for water conservation in denim is evident. Only 3 % of the earth’s water is contemporary, and round two-thirds of the worldwide inhabitants may very well be dealing with water shortages by 2025.
Beyond Double Zero, AGI Denim is making efforts to scale back its water footprint. It takes about 1,800 gallons of water to supply sufficient cotton for one pair of denims. Across all of its strains, AGI tries to make use of at the least 5 % and as much as 20 % post-consumer recycled supplies as an alternative of virgin cotton. Six months in the past, the mill started working with Renewcell to include its Circulose materials into its denim, permitting it to make use of recycled inputs with none high quality adjustments.
In one other uncooked supplies transfer, AGI Denim has began working with hemp as an alternative choice to cotton. By changing a portion of cotton in denims with hemp, which is a much less thirsty crop, AGI can scale back the water that goes into its denims.
“The earth is always becoming hotter, drier and more crowded, and the availability of water is becoming more challenging day by day,” stated Tekin. “Denim manufacturing is one of the world’s most water intensive processes, and it’s causing a huge environmental impact, so we have to find some solution.”
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