Most textile mills still use traditional dyeing methods. To enable the dye to take to the fabric, undyed rolls undergo many hours of rough treatment, including the use of a variety of chemicals, wear and tear by machines, large amounts of
hot and cold water; and treatment with up to 0.5 kg (1.10 pounds) of salt per kilogram (2.20 pounds) of fabric.
Technology Used:
Cold pad batch dyeing is a more environmentally sound and higher quality dyeing method. The process removes salt from the effluent, reduces the use of water and energy, reduces the volumes of effluent and occupies less space on the production
floor. It also uses fewer chemicals, and the switch to Cibacron C dyes further reduces the color carried in the effluent. The new dyeing system, specially designed for dyeing circular knits containing cotton, was developed by Beautech Ltd of Rock
Hill, South Carolina, United States. It is simple and compact, and the dyeing machine is driven at running speeds of up to 55 meters (60 yards) a minute while reducing water consumption by 88%.
Benefits: Reduced Water Pollutants, Reduced Solid Waste Production:
Details:
The process involved the purchase of two pieces of special equipment: a padding machine which dyes the fabric, and a trickle or rinsing machine. This purchase marginally increased the company's costs. The company promoted the environmental benefits
of the process, which enabled it to charge marginally more for the product to cover these extra costs. After about six months, the company began to notice an improvement in the environment and in consumer awareness. The fabric undergoes less
turbulence and so retains a smooth, uniformly colored appearance with added luster
and a soft drape and handle. Larger runs of fabric of the same color can be made·
Cost is comparable with traditional dyeing, but the quality is improved· The
company's image has improved as a result of the superior product.
Capital investment: 280 000 US$
Payback period: 8 months
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