Sustainable Denim

The Most Sustainable and Profitable Way to Make Denim

GREENDYE will transform the way denim is made. Our technology is three times more efficient and two times cleaner than a conventional indigo dyeing machine. With GREENDYE you are going to get sustainability and profitability.

 

Environmental friendly advantages

High Dyeing Efficiency

The GREENDYE indigo dyeing uses nitrogen technology to control the chemical process of dyeing. The nitrogen technology increases up to 3 times the pick-up of a conventional dye vat thanks to the longer dwelling time and the increase of the indigo concentration.

Chemical and Yarn Waste Reduction

It drastically reduces the use of hydrosulphite and caustic soda (> 50% compared to conventional) that are the main polluter in this process. That means you save 50% of cost for chemicals. Since the machine length is overall shorter than a traditional indigo dyeing machine, yarn waste can be reduced too.

Water Saving by HALF

The same indigo shade can now be achieved with 3 dyeing baths instead of 9 baths (water reduction by two thirds). The higher fixation of the indigo on the fibre allows a drastically reduced consumption of water in the washing phase. Water consumption in the finishing process can be reduced by around 50%.

Water footprint of GREENDYE in the textile supply chain

 

 

Extremely low Operating Expense

Compared to a conventional machine the GREENDYE is only two thirds of its length. Requiring less space, less operators and less spare parts with the same output. The amount of chemicals and water used in the daily business is HALF of a traditional indigo dyeing machine.

Nitrogen Technology - How it Works

  • The problem with the conventional method is timing. The time between dipping and skying is too short for diffusion and fixation of dyestuff to take place. 
  • This phase is basically absent in the traditional method.
  • With the nitrogen technology the oxidation is temporarily prevented. In the NOX chamber the dyestuff has enough time to diffuse and fixate on the yarn. 
  • This way the GREENDYE can pick up 3 times more dye with even higher indigo concentration.

Process of nitrogen technology compared to conventional technology

Accessible by design

Our machine is designed to be used by everyone. The GREENDYE comes with powerful assistive Human-Machine-Interface, which helps operators manage the denim production with minimal touch and easy navigation. The window in the NOX chamber is designed to facilitate easy operator handling and accessibility inside the machine.

Full Support from R&D to Finished Sample

We have installed a built to scale pilot machine and a fully equipped laboratory to support you with woven and finished denim samples that you can use to show your customers. The pilot machine is approx. 13 meters long and will reproduce exactly on a scale 1:10 the industrial process by producing samples 200 mm wide.

You will be able to show different samples of GREENDYE produced fabrics to your customer. This will help you test the market and decide which products to make in full production. We provide you with all the details for machine adjustment so that you can produce the fabric your customer wants.

With GREENDYE we offer fully integrated support for the whole technology from R&D to finished samples.

Expert Training at our Academy

The knowledge about the right dipping, squeezing, diffusion in nitrogen and oxidation is a key factor for your success in the market. Our denim academy enables you to send your staff for hands on training on the machine and focused education for a very deep understanding of the new technology. All free of charge. Only with the right knowledge and a deep understanding of the sustainable denim technology will you be able to outperform your competitors. We strongly believe that sustainable denim is the future way to produce denim. At our Denim Academy you can learn how to use this technology to your advantage.

Get in Touch with our Chief of Technology

 

 

Ansprechpartner

Stefano Agazzi
Chief of Technology and Products KARL MAYER ROTAL S.r.l.
Via Trento No. 117 38017 Mezzolombardo / Italy