Chemical ManagementSustainability

Cleankore eliminates hazardous potassium permanganate process in denim dyeing

The sustainable denim industry focuses on reducing the environmental and social impacts of denim production. Key initiatives include using organic or recycled materials, reducing water and energy consumption, implementing ethical labor practices, and promoting circular fashion to extend the life of denim products.

The distressed jeans that we see around everywhere undergo a wide variety of wet as well as dry treatments to get the desired effects. Potassium permanganate spray is done on jeans to take a bright effect on sandblast area. The usage of Potassium Permanganate in the industry causes more water consumption, creates a hazardous environment, and reduces worker safety.

Figure: Benefits of CleanKore technology

CleanKore’s patented technology is proven to significantly reduce costs throughout the denim manufacturing stages while lowering the carbon footprint and improving sustainability, including the complete elimination of the hazardous Potassium Permanganate spray. This also included a laser booster to achieve the bright white abrasion effect in the garment finishing process.

Sulphur dyeing of cellulosic yarn on a continuous warp dyeing machine has also been changed by keeping the cotton’s natural whiteness inside the fibers and just colouring the outside layer. Laser technology does a superb job of creating a worn-in effect on blue denim. This was impossible with sulphur black because the cotton gets dull and yellow.

The application of the technology in the denim business is pretty exciting. CleanKore maintains the interior of the yarn and stops the dye from penetrating, whereas conventional dyeing procedures completely cover the yarn with indigo dye. The end product is a yarn with a big, white center and a dyed border in appearance. This lack of dye penetration has numerous advantages for production and sustainability in black denim and others.

Figure: Original yarn bundle and the innovative yarn bundle difference.

This technology allows for a ready-for-retail garment without additional steps or Potassium Permanganate spray for brightness in the process. No new equipment or capital expenses are needed to implement this technology, including dark indigo, sulfur top/bottom, and sulpher black.

By using this technique, according to CleanKore, up to 15 liters of water, or the equivalent of five people’s daily water needs, and up to 0.51 kWh, or the energy used by five 100-watt light bulbs, can be saved per garment. The CleanKore technology also leads to a 10% to 20% increase in production throughput, as a result of a faster garment wash-down and the elimination of PP spray. Overall 80-90 percent of chemicals are reduced by implementation of this process.

This procedure actually brings and achieves a much faster garment wash down with excellent fastness to produce the market-driven look which can be a great value addition to Bangladeshi market. Building sustainable alternatives in our country through these value additions can severely create better emphasis on the environment. This technology applies to rope or slasher ranges, ring-spun or open end and dark indigo, sulpher top/bottom, and sulpher black. This process can gather a wide range of wash down on the same denim – from dark rinse to heavy abrasion with bleach. A greater degree of automation in laundry process can be achieved by this process. Fabric strength remains overall intact through the proper use of this technology. Worker safety and brand awareness can easily create e better impact the quality of denim products as a whole.

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