From the Sector

With the aim to help the denim industry reduce the environmental impact of its wastewater and move towards circularity, Archroma, G-Star RAW and Advance Denim have renewed their joint commitment to the production of aniline-free denim apparel based on Archroma’s DENISOL® PURE INDIGO 30.

Their joint aim is to produce high-quality denim in authentic blue shades without the aniline impurity carried through from the synthesis of standard synthetic indigo. In traditional denim production, this aniline remains bound with the indigo pigment on the fabric; the remaining aniline is discharged during the dyeing and washing process. This can be a problem because aniline is toxic to aquatic life and two-thirds of aniline waste currently ends up in wastewater discharge where it could potentially pollute waterways and the ocean.

Archroma developed DENISOL® PURE INDIGO 30 to answer this key challenge. A 30% pre-reduced indigo solution, DENISOL® PURE INDIGO 30 makes it possible to produce indigo-dyed denim without aniline impurities throughout the process.

Easy to use with automated dosing, DENISOL® PURE INDIGO 30 reduces the water needed for preparation, washing and wastewater treatment compared to indigo grains. It also reduces hazardous chemical consumption while allowing high reproducibility and creating the authentic and iconic deep indigo shades traditionally associated with denim.

G-Star RAW is working towards making 20% of its entire collection from Cradle to Cradle Certified® fabrics by 2025. Its partnership with Archroma and Advance Denim contributes to this goal, since the aniline-free DENISOL® holds a Gold Level Material Health Certificate from the Cradle to Cradle Products Innovation Institute. DENISOL® PURE INDIGO 30 is also compliant with other eco-standards and the requirements of leading retailers and brands.

Advance Denim, G-Star RAW and Archroma have previously collaborated to launch collections based on Archroma’s EarthColors® technology, which upcycles plant waste from the herbal industry to create sustainable colorways.

Textil Santanderina, a manufacturer of quality fabrics with controlled traceability, launched its Advanced Black denim collection in collaboration with Archroma.

The Advanced Black collection by Textil Santanderina uses Archroma’s new DIRESUL® EVOLUTION BLACK LIQ dyestuff to produce on-trend authentic black denim apparel with sustainability and resource savings. In addition to allowing fashion and apparel brands to choose eco-friendlier alternatives that demonstrate their commitment to protecting people and planet, Textil Santanderina’s new Advanced Black denim range also offers unique shade and wash-down effects.

Based on synthesis technology developed by Archroma, DIRESUL EVOLUTION BLACK LIQ delivers an overall impact reduction to 57%*, measuring its effect on human health, ecosystems and resources compared to standard Sulfur Black 1 liquid. Unlike traditional synthesis processes, it does not produce any ammonia, sodium salts waste or liquid effluents, and water consumption in the synthesis process is reduced by 73% for massive savings. The new DIRESUL dyestuff, when adopted with the full Archroma coloration system, delivers a new black color with on-tone wash-down effect and cleaner effluent at the mill.

Textil Santanderina and Archroma previously collaborated to produce Textil Santanderina’s aniline-free** indigo denim collection with the use of DENISOL® PURE INDIGO.

*As determined by Ecoterrae, a leading Spain-based sustainability consulting firm, through a Life Cycle Analysis (UNE-EN ISO 14044:2006) at the synthesis stage, using the ReCiPe 2016 Impact calculation methodology.
**Below limits of detection according to industry standard test methods.

Archroma, a global leader in specialty chemicals towards sustainable solutions, and Jeanologia, a world leader in sustainable and efficient technology development, joined forces to launch an eco-advanced alternative to the denim fabric washing process, including in some cases the mercerization, one of the most water-intensive and pollutant processes of denim fabric finishing.

It all starts with the spinning step where the cotton is turned into yarn. The second step is a pretreatment that will prepare the yarn for the dyeing step. The dyed yarn then goes through the sizing process, which is a treatment preparing it for weaving. At this stage, we have obtained a denim fabric that will go through a few more steps. First, the fabric may undergo a washing treatment or, in some cases, mercerizing treatment which consists of treating it with caustic soda in order to obtain a more lustrous, flat and less reddish blue and black denim.

In both traditional ways to clean the fabric, washing or mercerizing, multiple highly water intensive washings are required in order to restore optimal fabric pH and remove unfixed dyestuff and any undesired deposits or impurities from the fabric. One of such impurities released in the washing process is aniline, a substance that is classified as a category 2 carcinogen and considered toxic to aquatic life.

That is why Archroma and Jeanologia decided to team up and develop an alternative to the traditional fabric cleaning process and its subsequent water-intensive and water-polluting washings.

• The breakthrough alternative to the fabric cleaning concept presented by Jeanologia and Archroma combines the use of the aniline-free* PURE INDIGO ICON dyeing system of Archroma, and the water-free** and chemical-free “G2 Dynamic“ finishing technology of Jeanologia.
• The Archroma/Jeanologia solution allows to create aniline-free* denim, and improve the final aspect of the fabric through a fully chemical-free and almost water-free** cleaning alternative treatment.
• The Archroma/Jeanologia solution can also be used with additional Archroma coloration systems such as INDIGO REFLECTION or PURE UNDERTONES.

Umberto Devita, Business Development Manager at Archroma’s Competence Center for Denim & Casual Wear, who was the project leader for this new development, comments: “At Archroma, we strive to develop solutions in line with our principles of “The Archroma Way to a Sustainable World: Safe, efficient, enhanced, it’s our nature”. It was therefore very inspiring to work with a partner who shares the same values of developing efficient new processes to bring all know-how to our customers to maximize value – for denim that looks as good as the good it creates.”

For Jean-Pierre Inchauspe, Business Director of G2 Dynamic at Jeanologia, “this association is another step to change traditional, more polluting and water consuming processes in the textile industry for new ones using technology, improving, and boosting subsequent production stages up to the finishing of the garment, making them more efficient and allowing companies to be more competitive, increase productivity and offer a product that is completely sustainable with high quality.”

• 18+ metric tons of aniline are estimated to have been removed from the denim supply chain in about 3 years⁽²⁾.
• That represents 300'000'000+ pairs of jeans free of aniline, with 18'000+ garment workers, and aquatic life, protected from its toxicity⁽²⁾.

Archroma celebrates nearly 3 years of successfully converting the denim industry to aniline-free⁽¹⁾ pre-reduced liquid indigo.

Archroma launched its aniline-free⁽¹⁾ Denisol^® Pure Indigo in May 2018⁽³⁾.

Aniline is a key ingredient to make the indigo molecule. Unfortunately, during this process some aniline impurities are carried through into the indigo dyestuff. When the indigo is dyed on the fabric, a lot of the aniline impurity is locked into the pigment in the fabric. The remainder of the aniline impurity, approximately 300 metric tons annually, is discharged during dyeing. This can be an issue as aniline is toxic to aquatic life. In addition, exposure levels to factory workers can be high. The new Denisol^® Pure Indigo 30 liq was therefore developed as an aniline-free⁽¹⁾ indigo solution for designers, manufacturers and brand owners who long for authentic indigo inspiration.

Since the launch of Denisol^® Pure Indigo, several denim manufacturers, such as front-runner Absolute Denim, as well as Advance Denim, Azgard 9, Kilim Group, Nuevo Mundo, Rantex, Shasha Denim and Tuong Long, have taken the matter in their hands and converted their production or dedicated lines to aniline-free denim to brands and retailers.

The innovation is also supported by denim partners such as Be Disobedient and The Denim Window.

Archroma evaluates that, based on the total quantity of Denisol^® Pure Indigo sold until its introduction, its partners helped remove almost 18 metric tons of aniline from the denim supply chain. That represents an equivalent to about 300’000’000 pairs of jeans free of aniline and more than 18’000 garment workers protected from its toxicity⁽²⁾.

(1) Below limits of detection according to industry standards (tested & proven).
(2) Based on 15 minutes of work to produce one pair of jeans, produced over 8-hour working days and 300 working weeks per year.
(3) For the launch press release, click here.

Archroma today announced that Vietnam-based Tuong Long Co. Ltd (“Tuong Long”) is the first denim manufacturer in Vietnam to switch 100% of its production to Archroma’s aniline-free* Denisol® Pure Indigo.

Tuong Long Co. Ltd is a textile manufacturer based in Vietnam, whose plant is located near Ho Chi Minh City and employs 600 people producing up to 18,000,000 meters of fabric per year. Tuong Long manufactures and trades woven fabrics, particularly denim and khaki, stretch and non-stretch, for apparel brands in the USA, Japan, Europe, Korea, Taiwan, and Vietnam.

Archroma’s Denisol® Pure Indigo 30 liquid dye was first launched in May 2018 as a non-toxic way to produce the traditional, iconic indigo blue that consumers associate with denim and jeans.

During production, some of the aniline stays locked into the indigo pigment and is difficult to wash off the fabric. The remainder of the aniline impurity, approximately 300 metric tons annually, is discharged during dyeing. This can be an issue as aniline is toxic to aquatic life. In addition, exposure levels to factory workers can be high. As a result of its toxicity (more hazardous than alkylphenols) it is now starting to feature on the restricted substance lists (RSL) of some major clothing brands and retailers.

The new Denisol® Pure Indigo 30 liq was therefore developed as an aniline-free* indigo solution for designers, manufacturers and brand owners who long for authentic indigo inspiration.

Archroma, a global leader in color and specialty chemicals towards sustainable solutions, will be at Techtextil to launch its latest innovations and system solutions aimed to help textile manufacturers with optimized productivity and/or value creation in their markets.
Archroma offers a wide portfolio of dyes and chemicals aiming to increase sustainability and innovation along the entire value chain, from fiber to finish.
Archroma is reputed for its continuous flow of ground-breaking innovations, such as the EarthColors®, a range of dyes made from non-edible natural waste from the agricultural and herbal industry, or more recently, the purest indigo, Denisol® Pure Indigo, an aniline-free* synthetic pre-reduced liquid indigo launched in 2018.
At Techtextil, Archroma will present 10 solution systems and 4 innovations, and will hold an “Innovation Session” to present the most prominent of those for the first time ever: Appretan® NTR, a new nature-based binder. (See “Agenda” below).

The Archroma Way
The systems and innovations presented by Archroma have all been selected for their compliance with “The Archroma Way: safe, efficient, enhanced, it’s our nature”. The approach finds its origin in Archroma’s deep belief that it is possible to make the textile industry sustainable.
The Archroma Way is based on 3 pillars:

1. Safe - with the deeply rooted goal to protect people and our planet. Safe to use, safe to release and also safe to wear.
2. Efficient - with innovating application processes that minimize resources and maximize productivity, both in Archroma’s and its customers' manufacturing.
3. Enhanced – with the added value created from additional effects, functionalities and aesthetics.

At Techtextil, visitors will be able to discover how The Archroma Way can help them create value in their textile applications and markets.

Archroma, a global leader in color and specialty chemicals towards sustainable solutions, today announced that Thailand-based Absolute Denim will be the first denim manufacturer to switch 100% of its production to aniline-free* indigo dyeing.

Absolute Denim is a Thailand-based denim manufacturer producing high quality denim with a focus on eco-friendlier materials and processes. The company can produce up to 2 million meters of denim per month (that's approximately 1.5 million pairs of jeans!), for customers that include some of the biggest brands and retailers in the world.

Archroma’s Denisol® Pure Indigo 30 liquid dye was first launched in May 2018 as a non-toxic way to produce the traditional, iconic indigo blue that consumers associate with denim and jeans.

During production, some of the aniline stays locked into the indigo pigment and is difficult to wash off the fabric. The remainder of the aniline impurity, approximately 300 metric tons annually, is discharged during dyeing. This can be an issue as aniline is toxic to aquatic life. In addition, exposure levels to factory workers can be high. As a result of its toxicity (more hazardous than alkylphenols) it is now starting to feature on the restricted substance lists (RSL) of some major clothing brands and retailers.

The new Denisol® Pure Indigo 30 liq was therefore developed as an aniline-free* indigo solution for designers, manufacturers and brand owners who long for authentic indigo inspiration.

Archroma tested Denisol® Pure Indigo at Absolute Denim mill in Thailand. Archroma wanted to be sure that the new indigo dye would perform exactly the same as conventional indigo.

James Carnahan, Head of Sustainability at Archroma, comments: “At Archroma we continuously challenge the status quo in the deep belief that we can make our industry sustainable - but we cannot do it alone. Without forward-thinking manufacturers such as Absolute Denim to consciously adopt these eco-advanced innovations in their daily production, like our aniline-free* Denisol® Pure Indigo, we will not be able to move this industry forward on our resource-constrained world we live in. As consumers are increasingly aware of, and concerned about, climate change and ecological threats, this is not only the right thing to do - it is also good for business.”

“Deep down inside most of us want the world to be a better place for our loved ones and for future generations,” insists Vichai Phromvanich, Board Member, Absolute Denim, “starting with how we live, what we eat, what we wear, still trying to be cool, fashionable, still trying to be environmentally conscious. Archroma’s aniline free indigo project is therefore something we as a new generation manufacturer have supported from the beginning, by opening our doors for tests in the project phase, and now by sending out our articles to many of our customers. For us, after all, a nice pair of jeans looks even nicer without aniline!”

* Below limits of detection

Archroma, a global leader in color and specialty chemicals, will be presenting its innovative and sustainable denim solutions for manufacturers and brands at DenimsandJeans Vietnam 2018, on June 27 and 28.
From fiber to finish, Archroma offers a scope of possibilities for effects and colors, from the authentic roots of indigo to the most innovative and eco-advanced solutions. Archroma is a recognized leader in integrated solutions, offering best-in-class auxiliaries for bespoke process packages.
Visitors will be able to discover solutions designed to make denim in a more sustainable and responsible way, in particular:
DENISOL®, BRINGING INDIGO BACK TO ITS ROOTS - NOW ANILINE-FREE*
Archroma’s Denisol® range is a newly developed pre-reduced liquid indigo solution that is manufactured in Archroma’s award winning ‘zero liquid discharge’ manufacturing plant in Pakistan.

• Denisol® Indigo 30 liq is compliant with major official eco-standards and requirements from retailers, brands and fashion leading companies and helps to produce fabrics suitable for current eco-labeling such as bluesign® and GOTS.
• Responding to demands for a non-toxic alternative to the dyes that are used for the iconic and traditional indigo blue that consumers associate with denim and jeans, Archroma just announced the upcoming new Denisol® Pure Indigo 30.

ADVANCED DENIM, TOWARDS WATERLESS DENIM DYEING
Consider this: The water needed to produce one pair of jeans is said to be ~ 11'000 liters(1). With approximately 167 million pairs of jeans produced monthly(2), that is 1,837,000,000,000 liters of water consumed every month in the process! Based on the Denim-Ox and Pad/Sizing-Ox dyeing processes, Archroma’s multi-awarded ADVANCED DENIM, dyeing technology allows savings of up to 92% in water, 87% in cotton waste and 30% in energy, compared to a conventional denim dyeing process.
The technology has been adopted by brands like Patagonia and received the prestigious 2012 ICIS Innovation Award and Innovation with Best Environmental Benefit Award.

• Optisul® C, “soft colors” made easy
  Colors other than blue have been tricky to achieve in the past. With Optisul® C dyes, denim manufacturers can expand their color horizons with this range of six dyes especially designed to produce soft denim colors in continuous dyeing processes, as well as on coating and printing. Optisul® C affinity-free, sulfide-free dyes can easily be combined with each other to create garments suitable for wash-down treatments in a wide array of easily achievable and reproducible soft colors. They are suitable for GOTS and bluesign® approval.
• Diresul® RDT Ocean Blues, ocean-themed bright sulfur blue dyes
  Archroma’s Diresul® RDT Ocean Blues are a collection of vibrant, ocean-themed bright sulfur blue dyes. These best-in-class dyes and their auxiliaries bring out the best of indigo, improve workability, dyeing consistency and process safety.
  They can be combined with Denisol® Indigo 30 liq in bottoming/topping manufacturing routes for avant-garde blue styles. At the booth, Archroma will display an “illustration collection” of exciting indigo casts.
• Diresul® blacks & greys, a universe of greys and deep black and navies.
  Archroma’s dye portfolio of conventional and black Diresul® specialties allow to create a universe of greys and deep black and navies. From superficial to solid blacks for both extreme wash-down and stay black effects.

EARTHCOLORS, TRACEABLE FROM NATURE TO FASHION
As consumers increasingly aspire to functional, beautiful and meaningful clothing, brands and manufacturers are increasingly interested in the environmental impact of the denim industry. Archroma has placed sustainability at the heart of its innovation process to create products and processes that improve the industry’s sustainability.
The EarthColors patented range of “biosynthetic” dyes for cotton and cellulose-based fabrics, which are made from waste left over by the agricultural and herbal industry after extraction, such as almond shells, saw palmetto, or rosemary leaves. The latest NFC technology used on the end-product hangtags enables transparency and traceability through the supply chain to consumers.
The EarthColors allow to produce the earth tones that are coming strong: red, brown and green colors. They have been adopted by brands such as Patagonia, Kathmandu and G-Star, and won an OutDoor Industry Award 2017.

SOLUTION PACKAGES FOR SUSTAINABILITY
Brand owners and retailers around the world are taking action to evaluate the environmental impact of textile treatment, dyeing and finishing processes in response to consumer concerns.

Archroma recently introduced the ONE WAY Process Simulator, the last update of a calculation tool that supports its ONE WAY Sustainability Service introduced back in 2012. The new, online software can be used to mimic and compare products and processes, and thus calculate the ecological and economical profile of the final end-product.
Archroma’s portfolio of ZDHC MRSL-compliant chemicals and dyes is integrated into the ONE WAY calculation tool since 2013.
“Innovation and sustainability go hand in hand,” says Paul O’Prey, Head of Sales, Brand & Performance Textile Specialties, Archroma, Vietnam. “While developing new products and services, we always consider the environmental impact so they are as sustainable as possible. This can be seen in our innovative and eco-advance products, such as the water-saving ADVANCED DENIM and the aniline-free* Denisol® Pure Indigo.”