Water Saving Technology in Textile

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 Exhau

Water Saving Technology in Textile

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.

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.

● 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

(**** Data from Landmark website)

Information collected by Water Ambassadors:

Utility & services:

Sl No Machine Name Brand Origin Model Capacity No of Machine

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

Number of Dyeing machine for Bulk Production

Sl No Name/ Brand Origin Capacity (in Kg) Liquor Ratio M/C Feature

Number of Sample dyeing Machine

Sl No Name/ Brand Origin Capacity (in Kg) Liquor Ratio M/C Feature

Machine of Finishing Section

Sl No M/C Name Brand Origin Capacity (Ton/day)

 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.

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)

 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 1st wash Requirement

Length (%) 5.5 % 5%

Width (%) 1%

2 Color fastness to washing (30 minutes wash at 40c in 0.4% detergent)

Color Change : 4 Color staining: 4-5

3 Color fastness to rubbing (I.S.O 105x12-1993)

Dry: 3 Wet: 2-3

4 Spiral: 5

5 Pilling test: 4-5

6 Exhaustion Rate: 65%

• 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)

 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 1 st wash Requirement

Length (%) 5.5 % 5%

Width (%) 1%

2 Color fastness to washing (30 minutes wash at 40c in 0.4% detergent)

Color Change : 4 -5 Color staining: 4-5

Acetate: 4 Cotton: 4-5

Nylon : 4

Polyester: 4-5

Acrylic: 4

Wool: 4

3 Color fastness to rubbing (I.S.O 105x12-1993)

Dry: 4-5 Wet: 3-4

4 Pilling test: 4-5

5 Exhaustion Rate: 90%

Difference between classic reactive & Solophenyl/Avitera Dyes

Item Reactive dyes Solophenyl/ Avitara dyes

1 Process time 8-10 hours/ batch 4-6 hours/ batch

3 Water Consumption 94 ltr/ KG 28 ltr/ KG

Cost comparison of Classic Reactive & Solophenyl Dyes (LM)

Fastness Report of Landmark

Sl No Fabric Color Fabric Type Rubbing fastness Washing Fastness Fastness Pilling test Color Perspiration test Hand feel

1 Yellow

W.S.T Roadmap for 100% Cotton***

Year % Dyes Use Water Consumption (ltr/Kg) Time in hours

BD Intl' Minimizing BD Intl'

Total minimization of water if we follow International standard 40.5

*** All this depends on the fashion or on the color

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.

1.4 OBD (One Batch Dyeing): It is possible and recommended.

Cotton blended with polyester CVC/TC:

Classic 2 batch Dyeing (95% used right now)

Step 1 Scouring and Polyester Portion by Temperature of 130 C

Step 2 follows classic Reactive Dyeing Process.

Option 2 - Cationic Dye able PE Fiber blended

Step 1 Scouring and Polyester Portion by Temperature of 130°C.

Step 2 follows new Generation Reactive Dyeing Process (AVITERA).

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

Option 2 - Cationic Dye able PE Fiber blended