Water Saving Technology in Textile

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 polyester2. 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

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

Number of Dyeing machine for Bulk Production

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

1 Thies Germany 150 1:6 JET2 Thies Germany 300 1:6 JET3 Thies Germany 450 1:6 JET4 Thies Germany 450 1:6 JET5 Thies Germany 800 1:6 JET6 Thies Germany 800 1:6 JET7 Thies Germany 1200 1:6 JET8 Fongs China 600 1:8 JET9 Fongs China 800 1:8 JET

10 Fongs China 800 1:8 JET11 Fongs China 1500 1:8 JET

Number of Sample dyeing Machine

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

1 Thies Germany 15 1:6 S/ JET2 Thies Germany 60 1:6 S/ JET3 Santex Switzerland 40 1:6 S/ JET4 Santex Switzerland 40 1:6 S/ JET

Machine of Finishing Section

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

1 Open Compactor Bruckner Germany 7

2 Tube Compactor Sperttorumar 6-7

3 Stanter Bruckner Germany 8

4 Stanter Alkan Turkey 10

5 Spliting Bainco Italy 10

6 Dewatering Santex Switzerland 8

7 Dryer Santex Switzerland 8

8 Swiding M/C Lafar Italy 7-8

9 Back Swing 6

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 ltrIn solophenyl dyeing process required water is 402000 ltrSo 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

Acetate: 5

Cotton: 4-5

Nylon : 5

Polyester: 5

Acrylic: 5

Wool: 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 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 -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

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%

Cost comparison of Classic Reactive & Solophenyl Dyes (LM)Material 100% cotton Yarn Count 30’ S Color Blue

Item Classic Reactive Solophenyl SavingsDyes 2.5% 1.5% 1.00%Gluber Salt 54.50% 25% 29.50%Enzym 0.5/ kg 0.00/ kg 100%

CO2 Emission 50%

Dyeing Cycle Hrs 10 4 6hrs dyeing cycleManpower Cost 62.50%

Fastness Report of LandmarkSl No. Fabric

Color Fabric Type Rubbing fastness

Washing Fastness

Color Fastness Pilling test Perspiration

test Hand feel

1 Yellow

Low Twist Yarn 4 to 5 4 to 5 4 to 5 4 4 to 5 Very goodCombed with singeing 4 to 5 4 4 4 to 5 4 GoodCombed without singeing 4 4 4 4 to 5 4 MediumCarded with singeing 4 to 5 4 4 4 4 MediumCarded without singeing 4 4 4 4 4 Medium

2 pink


3 Blue


4 Grey


W.S.T Roadmap for 100% Cotton***Year % Dyes Use Water Consumption (ltr/Kg) Time in hours

BD Intl' Minimizing BD Intl'

2012

60 Classic Reactive Dye 100 70 42 10 7 to 820 New Generation RD 30 6 4

20 Solophenyl 25 5 4Total minimization of water if we follow International standard 53

2013


30 Solophenyl 25 7.5 4Total minimization of water if we follow International standard 44.5

2014


30 Solophenyl 25 7.5 4Total minimization of water if we follow International standard 40.5

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

Dyeing Proposal1. 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%

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.

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 consuming extremely 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.

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°CStep 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).

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.

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.

Engineering

Water Saving Technology in Textile