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“Without major changes in the way denim and
other garments are made, the pressure on our
environment will simply become intolerable”
Denim is one of the most iconic fabrics. Popularised by 19th century labourers requiring hardwearing garments, it has become a staple of the apparel industry widely used in workwear, fashion, footwear and even car interiors.
Our appetite for denim garments has created a vast industry which produces and processes more than 2.7 billion square metres of denim a year into around 1.2 billion pairs of jeans(1).
Denim makes up just a small part of the vast textile and garment manufacturing industry.
However, along with others, it is putting our planet’s finite resources under extreme stress consuming significant amounts of water and other raw materials, while producing harmful chemical and greenhouse gas emissions.
On the face of it, the clothing industry is not the largest source of environmental
stress. But without major changes in the way denim and other garments are made, consumed and disposed of, the pressure on our environment will simply become intolerable.
The solution lies in new sustainable technologies and changes in behaviour of all those in the value chain, including consumers.
Thankfully, new technologies are emerging, such as those we have developed at Xeros to reduce resource consumption, emissions and waste.
Our sustainable polymer technologies can help address the demands of legislators, NGOs, consumers, manufacturers, brands and enlightened retailers who are insisting we find ways to achieve more with less.
At Xeros our core purpose is to improve the sustainability of the clothes we wear throughout their lifetime.
Introduction
(1) Statistic Brain: Denim Jeans market analysis https://www.statisticbrain.com/denim-jeans-industry-statistics/ (2018)
1 Xeros Technology Group | Improving the Sustainability & Economics of Denim Finishing
Our products have multiple applications in the lifecycle of garments including garment dyeing, garment washing and denim finishing.
They improve the economics and sustainability of these processes by removing the need for large volumes of water, energy and chemistry.
We have designed them with industry leaders to help them achieve their objectives to increase levels of sustainability without compromising on cost or quality.
This presentation provides a summary of the benefits of using Xeros products in denim finishing.
Mark NicholsChief Executive Officer
Xeros Technology Group plc
“Improving the
sustainability of the
clothes we wear is
no longer an option;
it is an imperative”
Xeros Technology Group | Improving the Sustainability & Economics of Denim Finishing 2
““““
We urgently need to rethink our relationship with fashion just as the industry needs to rethink the ways in which it is produced. Innovative new solutions, such as those offered by Xeros, are urgently needed to reduce the damage being caused to the environment and improve the sustainability of the industry I have served for 25 years.
Krishan Hundal,Former Head of Technology and Procurement, Marks and Spencer
It has been an amazing experience to be involved with the team at Xeros reducing the environmental impact of denim garment washing. Their unique washing and processing techniques are leading the way to a more sustainable solution for garment wet processing.
Richard Woodhouse, T.S.Jeans Care U.K.
We need to have a flexible machine that will process at 4:1 Liquor Ratio or less using fewer utilities, chemicals and at lower temperatures than standard. I believe Xeros’ polymer XOrb™ & XDrum™ technologies offer these capabilities.
Peter Crews,Consultant in Textiles Finishing
““
3 Xeros Technology Group | Improving the Sustainability & Economics of Denim Finishing
““
““ Textiles are one of the biggest users of
water and chemicals. In our Xeros pilot project we’re
seeing improvements in Chemical reduction & Water
usage, which also supports our global 5 year sustainability
goals in Crystal International Group Ltd.
Protecting the ecosystem & Earth’s
natural resources is the mantra of sustainability.
Xeros saves water, effluent, pumice stone, energy and is the
best option for sustainability.
Warren Williams, Senior Manager R&D, Crystal International
Group Ltd
Sunder Belani,Managing Director
Ramsons Garment Finishing Equipment Pvt Ltd
4Xeros Technology Group | Improving the Sustainability & Economics of Denim Finishing
The denim industry is large, with around 1.2 billion pairs of jeans produced per annum. Each pair takes up to 70 litres of water in its finishing, with Xeros’ process reducing this consumption by up to 70%.
At Xeros we understand that the denim industry is extremely price competitive, with little appetite for customers to pay more for sustainability.
We also understand that pressure on factory gate prices will be unrelenting.
Xeros has developed products which go a long way to providing a solution - reducing inputs, emissions and processing time, whilst producing the best possible quality garments.
Sustainable denim finishing at a lower cost without compromise
Results from extensive testing of XOrbs in 500 and 1600 litre XDrum machines in Xeros’ Technology Centre
Conventional Xeros
Water Consumption 40-70 litres per jean 20 litres per jean
Chemical Consumption ~150 g 50 g
Temperature (Affecting Energy Consumption)
20-60 °C 20-40 °C
Cycle Time 30-45 mins 15 mins
Pumice Stones
Typical ratio 500g/kg (wt stone / wt garment) Zero
Xeros Benefits in Denim Finishing
5 Xeros Technology Group | Improving the Sustainability & Economics of Denim Finishing
Products delivering sustainability
Denim Process Cycle
Xeros’ process works with conventional or biochemistry
Xeros’ proprietary XOrbs™ replace pumice while reducing water and chemistry consumption. They do so in a single process cycle, using the proprietary XDrum™ design.
Xeros’ XDrum uses XOrbs to produce an authentic stone wash look. Unlike pumice they last for a very large number of cycles before being recycled into new XOrbs.
Xeros’ XOrb cycles can be tuned to produce any and all desired product outcomes - stone washing, surface effects and shading.
XDrum denim finishing machines automate the process of adding and removing XOrbs from the cycle. Thereby reducing labour intensity, increasing efficiency and reducing costs.
The Xeros process offers many significant benefits over conventional methods.
LOADING
SOFTENING
WETTING
RINSING
RINSING
ABRASIONDESIZING
WASHING BLEACHING DRAINING
Cellulase (Enzyme)
Pumice removed
Detergent and/or Amylase (Enzyme)Detergent
Garments often moved to a seperate
machine
Garments moved to
dryer
Sodium hypochlorite, potassium permanganate, ozone or
alternatives, including enzymes
Garments
Neutralisation
Softener
Pumice
Detergent
Unlike conventional processes, Xeros undertakes
all operations in one machine and with shorter cycle times
Xeros Technology Group | Improving the Sustainability & Economics of Denim Finishing 6
Reduced backstaining with the Xeros process
Precise stone washing effect, shading and other surface effects achieved with the Xeros process
Without compromise, delivering equivalent or better products than conventional processes.
7 Xeros Technology Group | Improving the Sustainability & Economics of Denim Finishing
With the Xeros process, manufacturers can achieve
any and all desired outcomes - stone washing,
surface effects and shading using a single machine...
with less inputs, less emissions and less time
Xeros XT450 Sample Garment Finishing Machine
Xeros Technology Group | Improving the Sustainability & Economics of Denim Finishing 8
Xeros Technology Group© Copyright Xeros 2019
Xeros, Xeros Technologies, XOrb, XDrum and XFiltra are all registered trademarks of Xeros Technology Group plc.
Unit 2 Evolution, Whittle WayAdvanced Manufacturing Park
Catcliffe, RotherhamS60 5BL
+44 (0)114 269 [email protected]
www.xerostech.com
