The
Problem
Conventional denim production utilizing slasher dyeing is a major contributor to water pollution and environmental harm, relying on toxic chemicals and excessive resources. Traditional methods are unsustainable, highlighting the urgent need for cleaner, eco-friendly solutions.
Large Scale
Production
The slasher dyeing process is a widely used method in large-scale denim production, where yarn is repeatedly dipped into multiple heated vats of synthetic indigo dye mixed with alkalis to achieve the desired color saturation and fastness.
This process typically involves 6 to 12 dips, with each dip followed by oxidation to fix the dye onto the yarn.
On an industrial scale, slasher dyeing is carried out in massive machines capable of processing thousands of meters of yarn in continuous runs.
Carbon Emissions
Conventional denim dyeing is highly energy-intensive, requiring large amounts of energy to heat water to high temperatures for multiple dyeing and rinsing cycles. This not only increases production costs but also significantly contributes to carbon emissions.
Water Intensive
Conventional denim dyeing is extremely water-intensive, requiring large quantities of water for every stage of the process, from preparing dye baths to repeated dipping and rinsing cycles. Each pair of jeans can consume up to 3781 liters of water during production.
Toxic Chemicals
Conventional denim dyeing relies heavily on toxic fixing agents like sodium hydrosulphite and alkalis such as caustic soda to bond the dye to the yarn. These chemicals generate highly toxic effluent that is difficult to treat and often ends up contaminating local water systems. The effluent contains harmful substances, including heavy metals and carcinogens, which pose serious risks to aquatic ecosystems and human health.
Wastage
Conventional denim production operates on such a large scale that it often results in significant wastage due to overproduction and unsold inventory. Manufacturers typically produce in bulk to meet projected demand, but any deviation from these forecasts leads to excess stock
