New water-saving dyeing process for denim and casual wear

Denim overdyed using Pad-Ox G2
Denim overdyed using Pad-Ox G2. Photo courtesy of Jeanologia

Archroma, a Swiss-based provider of specialty chemicals, and Jeanologia of Spain, announced the launch of Pad-Ox G2 Cold, a water-saving dyeing process. Archroma initially introduced its eco-advanced Pad-Ox dyeing process for woven fabrics, and then used it as part of its ADVANCED DENIM concept. By combining the oxidation and fixation steps, it is possible to shorten the dyeing process and thus realize substantial resource savings in water, wastewater, cotton waste, and energy.

Over the years the company worked with its textile manufacturers and partners to improve the Pad-Ox process, in particular woven applications such as chinos and casual wear. To achieve maximum positive impact, Archroma is using its Diresul range of low sulfide sulfur dyes and, more recently, its plant-based range of EarthColors. A wide selection of dyes from these two ranges have received the Cradle-to-Cradle Product Innovation Institute’s Platinum Level Material Health Certification.

Meanwhile, Jeanologia has been working on the technology side, with laser and eco-finishing solutions for more than 25 years. In 2008, the company introduced its G2 Dynamic, the first ozone treatment for continuous fabric that reduces the amount of water and chemicals used, while at the same time saving costs at the mill and eventually at the garment finishing facilities. This technology makes fabric more stable and consistent and prepares the fabric better for the use of other technologies like laser. This machinery can be used along with Pad-Ox technology to help cleaning fabric thus improve fastness results, while it allows the process to work at room temperature.

Jeanologia G2 Dynamic machine
Jeanologia G2 Dynamic machine. Photo courtesy of Jeanologia

Archroma and Jeanologia teamed up and combined their expertise in sustainable dyeing and finishing technologies. The objective was to improve the Pad-Ox dyeing process even further in one area that still offered room for positive impact: temperature and fastnesses. After several months of development, they came up with a way to apply the Pad-Ox dyeing process at room temperature, while still improving fastnesses and allowing higher contrasts after washdown. A binder-free technology to obtain end articles that are softer and have greater color durability to repetitive washing and solidity against rubbing than other wash-out processes.

The new Pad-Ox G2 Cold dyeing process works thanks to the insertion of a very small machinery into the existing finishing range process, using cold processing and thus operating with much less water, carbon footprint and energy than traditional benchmark fabric finishing processes, while retaining the water and other resource savings offered by the Pad-Ox technology.