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.

• 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.

In the latest short film released on the Monforts YouTube Channel – captured at the recent Denim Première Vision show in London – some of the leading global manufacturers discuss their initiatives for more sustainable denim production.

Cone Denim, based in Greensboro, North Carolina, for example, can lay claim to having put in place its first environmental control measures back in the 1940s when the company first started recycling its water.

“It was a method of efficiency even back then, eighty years ago,” says Gabriel Magopat, of the company’s UK customer service centre, “but  producing high quality products is another method of being sustainable and of being efficient, and I think that’s what Cone stands for. We have an amazing history.”

Cone Denim is known for its signature S Gene® stretch denims which have traditionally incorporated polyester components to provide the stretch. It has now partnered with Intrinsic Advanced Materials of Gastonia, also in North Carolina, to introduce patent-pending CiCLO stretch polyester fibres into its denim collections. 

While still being synthetic based, CiCLO polyester is able to biodegrade in marine environments, wastewater treatment plants and landfill conditions, at rates similar to natural fibres like wool. 

This more sustainable solution for stretch is also being introduced to China for the first time by another leading denim supplier, Advance Denim.

“Advance Denim is spending its resources on being the most technologically advanced company in China, and also the most sustainable,” says Mark Ix, the company’s Director of Marketing. “We are investing heavily in our manufacturing to save both water and chemicals to create cleaner products.”

Monforts denim customer Berto is a family-owned company with its main denim mill in Bovolenta, a small rural town near to Padua in the north east of Italy, where respect for the environment has always been a must.

“The family has always been focused on respect for the environment,” says Berto’s Marketing Manager Francesca Palento. “In particular, we have a river next to the company from which we take our water for production and we then return it cleaner than it was before. We are also now producing GOTS and Global Recycling Standard jean produced with yarns made from our own internal waste production.”

Pakistan’s Soorty has recently received Cradle to Cradle Gold certification – the most stringent and exacting sustainable standard currently in existence – for its Pure D range of denims. These are produced using the company’s proprietary Zero Waste Water dyeing technology, in combination with the most advanced Monforts finishing machines. 

“Our very latest collection is called Climate Jeans, because every single product we now produce draws attention to the climate emergency we are living through right now,” says Eda Dikman, Soorty’s Marketing Communications Manager. “Sustainability is very important to us because we produce at scale and all of the actions we take reflect on the planet.”

As the global textile industry’s most comprehensive sourcing summit for the spring / summer season, Intertextile Shanghai Apparel Fabrics is naturally the ideal place to find the latest developments in product innovation and sustainability. This is especially true in the fair’s Beyond Denim zone, which this edition will feature over 110 exhibitors from China, Japan, Pakistan, Turkey and elsewhere. Adding to a total of some 3,300 exhibitors from around 22 countries and regions, they provide sourcing options for the entire industry, from fabrics for ladieswear, menswear, suiting, shirting, lingerie and swimwear to high-end wool fabrics, original pattern designs, functional & performance fabrics, sustainability products & services, digital printing technologies, garment & fashion accessories and more.

Denim enriched with volcanic ash: the latest innovation from Orta Anadolu
Volcanic ash is not uncommon in beauty products – it is known as Mother Nature’s skin purifier after all, and used as an exfoliator for example – but it is far less common in the textile industry. Orta Anadolu are set to change that with their BIOWARE denim which is enriched with mineralised volcanic ash to create an odour absorbing effect. This technology captures and absorbs odour compounds that would normally pass through the fabric, neutralising bad bacteria while retaining the helpful bacteria that common deodorisers, which contain harsh substances, normally eliminate. This leads to a more environmentally friendly product that is better for the user’s skin.

Orta will also be presenting BIOCHARGE at Intertextile, which, according to the company, is the world’s first denim fabric for muscle wellness. Infused with minerals, Orta state that BIOCHARGE is medically proven to refresh muscles, relieve muscle tension and optimise body balance. They will also present their BOUNCE stretch range, with high elasticity and a ‘street’ style, while CHRONICLE, another in their S/S 19 range, is a blend of heritage and future styles.

US Denim Mills blend tomorrow’s technology with yesterday’s style
Another innovative denim firm exhibiting at Intertextile Shanghai, and another blending old and new, is US Denim Mills. According to the company, their collection at the fair will “harness tomorrow’s textile advances to revitalise the great style visions of the past by adding fashion, comfort, performance and sustainability advantages to authentic denim looks.” This collection includes:

• Selvedge: using the company’s legacy selvedge looms to produce bi-stretch ‘SelvedgeX’ while experimenting with blends of natural yarns and high-tech fibre blends in its ‘HeritEdge+’ range
• Stretch: including ‘Flex 360’ bi-stretch denim with a slight cross-bias freedom, and ‘Modern Stretches’ with a higher stretch range for intense comfort
• SoftWear: advanced finishing treatments for superior soft touch from natural fibre blended yarns and softness-selected weaves
• Sustainable: new additions to the range of recycled and natural ‘GreenEgo’ denims

Kipas Denim step up their sustainability efforts
Well aware of the effect denim production has on the environment, Kipas Denim’s multi-faceted programme to address this is one of the most comprehensive in the denim sector. Their recycled yarn initiative includes recycling waste yarn from the production process, while it also takes waste cotton yarn and blends it with REPREVE® fibres to create an eco-friendly denim fabric. Kipas also uses BCI cotton and organic cotton, and targets each to be 15% and 5% of total consumption, respectively. Furthermore, their Conservablue technology aims to reduce the environmental impact of the dyeing process by eliminating the use of rinsing overflow boxes before and after the indigo dye boxes, as well as ensuring 100% of applied dyestuff remains on the yarn in the rinsing bath.

As well as the overseas offerings, a wide range of domestic denim exhibitors covering all price and quality points will also feature in Beyond Denim. Some of the more notable brands participating include Advance Denim, Black Peony, Guangzhou Foison and Prosperity Textile.

Denim’s ‘next move’ to be debated in INVISTA panel discussion
The market is changing and so must apparel and textile manufacturers. Low prices and discounts are no longer driving sales the way they used to. Today’s consumer wants better quality, appreciates new technology and is evolving their casualwear style. This is the premise behind the INVISTA-sponsored panel discussion which will take place on day 1 of the fair. Titled ‘Denim’s Next Move – New Opportunities to Keep Growing Sales of Jeans and Casualwear at Retail’, participants will learn what consumers really want in jeans and casualwear, the return of chinos and new fabric technologies that are energising casualwear.

The panel will be moderated by Jane Singer, Director and Head of Market Development at Inside Fashion. Panellists will include representatives from Advance Denim, Guangzhou Conshing Clothing Group, Prosperity Textile and Texhong who will share their latest innovations that will help brands and retailers drive sales and profits.

In addition to Intertextile Shanghai Apparel Fabrics, four other textile fairs also take place at the National Exhibition and Convention Center: Yarn Expo Spring, Intertextile Shanghai Home Textiles – Spring Edition, fashion garment fair CHIC and knitting fair PH Value.