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INNOVATIONS IN TEXTILE PROCESSING
DEMAND EFFICIENCY
• Influence industry to choose cotton
• Market the advantages and flexibility of cotton
• Capitalize on internal development
• Capitalize on external collaborations and partnerships
Cotton Incorporated Developments
Industry Developments
GLOBAL SUPPLY CHAIN MARKETING
COTTON INCORPORATED TECHNOLOGIES
Moisture Management
Water Repellency Stretch
ADOPTIONS AT RETAIL
• Cotton Incorporated is leading the way in researching technologies for sustainable cotton manufacturing
• A World of Ideas book introduces market ready technologies that reduce water, energy and chemistry
• http://cottontoday.cottoninc.com
A WORLD OF IDEAS BOOK
SCOUT & EVALUATE
Spinning Knitting/Weaving Dyeing Finishing
PRIMAGREEN Enzymes • Are biodegradable • Are made from renewable resources • Can replace corrosive chemistry • Can lower the use of water and energy
PRIMAGREEN NEUTRAL PROCESS
Conventional Scour/ Conventional Bleach
Acid Cellulase
Neutralization Incoming Water Neutralization
Dye Fixation
Dye Exhaustion
Cellulase Inactivation
Conventional
Incoming Water Neutralization
Dye Fixation
Neutral Cellulase/ Dye Exhaustion
Enzymatic Scour/ Enzymatic Bleach
Enzymatic
Neutral Process - Each pH adjustment increases: • Processing time • Chemical usage • Potential for fabric damage
PRIMAGREEN COMPARISON Dark Shade
TIME WATER STEAM ENERGY ↓23% ↓84% ↓20% ↓25%
PRIMAGREEN COMPARISON Medium Shade
TIME WATER STEAM ENERGY ↓27% ↓63% ↓34% ↓28%
PRIMAGREEN COMPARISON Light Shade
TIME WATER STEAM ENERGY ↓30% ↓62% ↓45% ↓27%
PRIMAGREEN • Ability to combine processes • Work at a neutral pH • Low processing temperatures • More efficient processing
Dye
Bleaching Enzyme
Scouring Enzyme
• Garment jet dyeing machine
• Open pocket and high speed system
• Great flexibility
• Standard dyeing
• Special dye effects like ‘rain’ finishing, spotting, tie-dye and vintage
ECO-DYEING SYSTEM
VERSATILITY
More operations with the same machine.
HIGH SPEED
Increase dyestuff penetration improving dye quality and reproducibility. Reduced tangling, abbrasion and garment manipulation.
REDUCED PROCESSING TIME
Eleminate intermediate steps. Water heating. Dye time.
Low Impact 1:3 Liquor Ratio
Up to 70% reduction in Water, Auxiliaries and Energy.
WaterAuxiliaries
Energy
ECO-DYEING ADVANTAGES
Ice Batik
Kit Batik
Antarctic Batik
ECO-FRIENDLY DENIM FINISHING
• Produce elaborate, precise, custom designs • Easy to design and reproduce • Eliminates need for sandblasting and manual
scraping • Reduces water, chemical and energy consumption
GFK LASER SYSTEM
GFK LASER SYSTEM
laser creates hand sanded effect
laser creates localized areas of destruction
• Achieve washed-down, vintage look • Waterless washing machine utilizes ozone • Reduces water, chemical and energy consumption
G2 OZONE
• Create superior handfeel by applying nanobubbles of air, water, and softener
• Eliminates need for a chemical bath and discharge
• Reduces energy, water, and chemical consumption
E-SOFT TECHNOLOGY
VSEP RECYCLING • Vibratory Shear Enhanced Processing
• Membrane based water recycling technology
• Patented technology owned by New Logic Research
• Range of applications
• Auto industry – Coolant water recycling • Bottled water – Water purification • Pulp and paper – Effluent treatment • And now textiles – Water and indigo recycling
VSEP RESULTS Rinse Water H2O After
VSEP H2O After
RO Indigo
Concentrate
VSEP RESULTS
Successful implementation of the VSEP unit in denim mill.
Roughly 100% of indigo can be reused in slasher dye bath.
70% of water is able to be recycled back into the dye or rinse processing stage.
Up to 75 tons of reusable water generated per day by reverse osmosis unit.
COOL TRANSFER PRINTING
• Revolutionary print technology for cotton • Transfer prints from paper to fabric • Transfer printing used to be only for synthetics • Ability to print on 100% cotton
COOL TRANSFER PRINTING Efficient Flexible
Cost effective Eco-friendly
HIGH QUALITY
• Industry continues to make great strides in responsible processing
• Innovations are available throughout the supply chain that improve efficiency and meet downstream demands
• Cotton Incorporated is actively pursuing technologies that continue to give cotton the advantage
THE COTTON ADVANTAGE