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SUSTAINABLE
PRODUCTION
DYES/PAINT INDUSTRY
SANVEE READLAN
Contents
Introduction ................................................................................................... Error! Bookmark not defined.
Textile Dyes ............................................................................................................................................... 3
POLLUTION PREVENTION AND CONTROL ..................................................................................................... 5
KEY ISSUES..................................................................................................................................................... 5
Environmental Impact................................................................................................................................... 6
Remedy and Conclusions .............................................................................................................................. 7
GREEN CHEMISTRY IN INDUSTRY .............................................................................................................. 7
USE CHEMICALS THAT HAVE LESS ENVIRONMENTAL IMPACT ............................................................. 7
USE CATALYSTS TO INCREASE REACTION EFFICIENCY .......................................................................... 8
USE LESS ENERGY .................................................................................................................................. 8
WASTE NOT ........................................................................................................................................... 8
Optimization of the dyeing processes to reduce the environmental impact of the textile industry ........... 8
SUSTAINABILITY REPORT (HUNTSMAN)...................................................................................................... 10
SUSTAINABILITY ...................................................................................................................................... 10
INCOMING SUPPLY.............................................................................................................................. 11
PROCESS MANAGEMENT .................................................................................................................... 12
PRODUCT INNOVATION ...................................................................................................................... 12
DISTRIBUTION ..................................................................................................................................... 13
DATA ON PERFORMANCE ....................................................................................................................... 14
SUSTAINABILITY REPORT (DYSTAR)............................................................................................................. 18
SUSTAINABILITY STRATEGY ..................................................................................................................... 18
CONSERVING PLANETARY RESOURCES ............................................................................................... 19
RAW MATERIALS ................................................................................................................................. 19
WATER................................................................................................................................................. 20
WASTEWATER ..................................................................................................................................... 20
GREENHOUSE GAS (GHG) EMISSIONS................................................................................................. 21
CARING FOR PEOPLE ............................................................................................................................... 21
OCCUPATIONAL HEALTH AND SAFETY: ............................................................................................... 21
Human Rights ...................................................................................................................................... 22
RESPONSIBLE PRODUCTS AND SOLUTIONS : .......................................................................................... 22
SERVICES ................................................................................................................................................. 24
COLOR SOLUTIONS INTERNATIONAL ...................................................................................................... 24
ECONFIDENCE ......................................................................................................................................... 24
SUSTAINABLE TEXTILE SOLUTIONS ......................................................................................................... 25
TEXANLAB ............................................................................................................................................... 26
GREEN CHEMISTRY DESIGN .................................................................................................................... 27
Conclusion ................................................................................................................................................... 32
Introduction
During the process of manufacturing, textile has to go through a long process of chemical
and non-chemical treatments. It is estimated that over 10,000 different dyes and pigments
are used industrially and over 7 x 105 tons of synthetic dyes are annually produced
worldwide. Textile materials can be dyed using batch, continuous or semi-continuous
processes. The kind of process used depends on many characteristics including type of
material as such fiber, yarn, fabric, fabric construction and garment, as also the generic
type of fiber, size of dye lots and quality requirements in the dyed fabric.In the textile
industry, up to 200,000 tons of these dyes are lost to effluents every year during the dyeing
and finishing operations, due to the inefficiency of the dyeing process. Unfortunately, most
of these dyes escape conventional wastewater treatment processes and persist in the
environment as a result of their high stability to light, temperature, water, detergents,
chemicals, soap and other parameters such as bleach and perspiration. In this context, and
considering the importance of colored products in present day societies, it is of relevance
to optimize the coloring process with the objective of reducing the environmental impact of
the textile industry.
Textile Dyes
ACETATE RAYON DYES - It was developed for cellulose acetate and some synthetic fibres.
ACID DYES - It is used for coloring animal fibres via acidified solution (containing sulphuric
acid, acetic acid, sodium sulphate, and surfactants) in combination with amphoteric
protein.
AZOIC DYES - It contain the azo group (and formic acid, caustic soda, metallic compounds,
and sodium nitrate); especially for application to cotton.
BASIC DYES - These are amino derivatives (and acetic acid and softening agents); used
mainly for application on paper.
DIRECT DYES - These azo dyes, and sodium salts, fixing agents, and metallic (chrome and
copper) compounds; used generally on cotton-wool, or cotton-silk combinations
MORDANT OR CHROME DYES - These are metallic salt or lake formed directly on the fibre
by the use of aluminium, chromium, or iron salts that cause precipitation in situ
VAT DYES - It impregnated into fibre under reducing conditions and deoxidized to an
insoluble color.
Considering the fact that the textile dyeing process is recognized as one of the most
environmentally unfriendly industrial processes, it is of extreme importance to understand
the critical points of the dyeing process so as to find alternative, eco-friendly methods.
• Avoid the manufacture of toxic azo dyes and provide alternative dyestuffs to users such as
textile manufacturers.
• Reuse by-products from the process as raw materials or as raw material substitutes in
other processes.
• Use high-pressure hoses for equipment cleaning to reduce the amount of wastewater
generated.
A dye and pigment manufacturing plant should prepare and implement an emergency plan
that takes into account neighbouring land uses and the potential consequences of an
emergency.
KEY ISSUES
The key production and control practices that will lead to compliance with emissions
guidelines can be summarized as follows:
• Avoid the manufacture of toxic azo dyes and provide alternative dyestuffs to users such as
textile manufacturers.
• Replace highly toxic and persistent ingredients with less toxic and degradable ones.
• Use equipment wash down waters as makeup solutions for subsequent batches.
• Minimize wastage by inventory control and find uses for off-specification products.
Environmental Impact
Dyes cause a lot of problems in the environment. The problems which are caused in
environment by dyes are given below:
1. Depending on exposure time and dye concentration, dyes can have acute and/or chronic
effects on exposed organisms.
2. The presence of very small quantities of dyes in water (less than 1 ppm) is highly visible
due to their brilliance.
3. The greatest environmental concern with dyes is their absorption and reflection of
sunlight entering the water. Light absorption diminishes photosynthetic activity of algae
and seriously influence on the food chain.
4. Dyes can remain in the environment for an extended period of time, because of high
thermal and photo stability. For instance, the half-life of hydrolysed Reactive Blue 19 is
about 46 years at pH 7 and 25 °C.
5. Many dyes and their breakdown products are carcinogenic, mutagenic and/or toxic to
life. Dyes are mostly introduced into the environment through industrial effluents.
6. Textile dyes can cause allergies such as contact dermatitis and respiratory diseases,
allergic reaction in eyes, skin irritation, and irritation to mucous membrane and the upper
respiratory tract.
Public perception of water quality is greatly influenced by the color. So, the removal of
color from wastewater is often more important than the removal of the soluble colorless
organic substances. Removal of the dyes from the textile wastewater is often very costly,
but a stringent environmental legislation has stimulated the textile sector in developing
wastewater treatment plants.
• In the end however, the company makes more profit due to less waste, protects the
environment, and becomes more competitive.
• However it is consumers that must make the big changes: we must develop a less
wasteful more sustainable approach to consumer product.
Ex: glucose can be used instead of benzene (a known carcinogen) in the production of
certain plastics, however, using a food crop (corn) to make glucose to make plastic takes
this land and food away from people/livestock.
• Switching to more efficient furnaces that create more energy using less fuel
WASTE NOT
Recycle the material in industry that can be used again .
• Avoid losing energy through heat loss, try to trap the heat in a “closed loop” system to use
it again
• Closed loop systems can also gather hazardous substances to prevent them from being
released into the environment.
Environmental problems with used dye baths are related to the wide variety of different
components added to the dye bath, often in relatively high concentrations. In the future,
many of textile factories will face the requirement of reusing a significant part of all
incoming freshwater because traditionally used methods are insufficient for obtaining the
required water quality.
However, due to dwindling supply and increasing demand of water in the textile industries,
a better alternative is to attempt to further elevate the water quality of wastewater effluent
from a secondary wastewater treatment plant to a higher standard for reuse. Thus far very
little attention has been paid to this aspect
Therefore, the investment in the search for methodologies to more effective treatment of
these effluents can be much smaller than that spent in tertiary treatment to remove these
products in low level of concentrations and in the presence of much other interference.
This requires action that the cost / benefit are reviewed and the development of new
techniques for wastewater treatment capable of effective removal of these dyes is
intensified and made economically viable.
An alternative to minimize the problems related to the treatment of textile effluents would
be the development of more effective dye that can be fixed fiber with higher efficiency
decreasing losses on tailings waters and reducing the amount of dye required in the dyeing
process, reducing certainly improve the cost and quality of the effluents.
SUSTAINABILITY REPORT (HUNTSMAN)
HUNTSMAN is a global manufacturer of chemicals people use every day. Through their five
divisions, they operate in more than 30 countries around the world, employing over 14,000
associates at more than 100 manufacturing and research and development sites. They
serve a broad and diverse range of consumer and industrial end markets, including: energy
and fuels; transportation; home life; paints and coatings; textiles; and construction. Our
products address customers’ needs and help provide solutions to some of the world’s
greatest challenges.
They manufacture MDI-based polyurethanes used to produce: energy-saving
insulation; comfort foam for automotive seating, bedding and furniture; adhesives;
coatings; elastomers for footwear; and composite wood products.
They produce technologically advanced epoxy, acrylic and polyurethane-based
polymer products that are replacing traditional materials in aircraft, automobiles
and electrical power transmission. Their products also used in coatings,
construction materials, circuit boards and sports equipment. Pigments and
Additives mainly titanium dioxide pigments, color pigments, functional additives
and timber and water treatment chemicals. Pigments and additives add
performance and colour to thousands of everyday items from paints, inks, plastics
and concrete to cosmetics, pharmaceuticals and food.
In Textile Effects they are major global manufacturer of textile dyes, digital inks and
chemicals that enhance colour, provide a broad shade gamut for digital printing, and
improve fabric performance such as wrinkle resistance, UV-blocking and water and
stain repellency. Their solutions provide operational and environmental excellence
across the apparel, home and technical textiles end-use markets. Products primarily
based on amines, carbonates, surfactants and maleic anhydride. End uses include:
agrochemicals; oil and gas and alternative energy solutions; home detergents and
personal care products; adhesives and coatings; mining; and polyurethane/epoxy
curing agents are the performance products they produce.
SUSTAINABILITY
As a chemical manufacturer, Huntsman plays a role in supporting the development of
alternative sources of energy – like wind and solar – and in the construction and
transportation industries, where their innovative products are helping customers conserve
and use energy more efficiently.
In many of manufacturing facilities, they have developed highly integrated energy
management systems, are constantly looking at ways to make their processes and
equipment more efficient in order to reduce our total energy consumption and improve our
energy intensity rate. Major initiative taken by company to conserve the world’s energy
resources in four major areas.
Incoming Supply
Process Management
Product Innovation
Distribution
INCOMING SUPPLY
Huntsman took a close look at its own method for distributing propylene oxide. Huntsman
ships 180 million to 210 million pounds of propylene oxide a year from its plant in Port
Neches, Texas, to other Huntsman chemical plants in the U.S. Gulf Coast region.
The company takes advantage of the synergy of co-siting by sharing utilities and associated
costs with the other companies. Together with their co-siters, Huntsman is continually
looking for synergies that can be exploited to reduce the site’s CO2 footprint.
One recent initiative involves waste heat from a Huntsman plant that is used to heat
process water for another company on the site, resulting in an annual CO2 savings of
15,000 tons between the companies.
the site entered an agreement with the government to lower its energy usage by two
percent per year. Along with other initiatives designed to meet this target,
The plants at the site use a centralized pipeline system for raw product delivery rather than
alternative carbon-intensive transport methods. By using pipelines for raw materials
delivery, the CO2 savings compared to road transportation is 90 percent.
Huntsman optimized its manufacturing processes, enabling it to use less pure raw
materials to produce the same amount of product. This, in turn, lowers steam and energy
requirements in the complete manufacturing chain. As a result of all the initiatives on the
site, over the past 10 years, the site has reduced the greenhouse gas impact from its
polyurethane production by 30 percent.
Huntsman uses pipelines for delivery of big bulk loads to save energy involved in transport.
Use of pipelines impacts all three targets of sustainability: people, by using a safer delivery
system that keeps trucks off the road and eliminates handling risks; planet, by reducing
CO2 emissions; and profit, by reducing the costs for storing onsite inventory.
“less expensive and more efficient way to get products to and from their plants” Use of
pipelines is one way to make their logistics more efficient.
PROCESS MANAGEMENT
The Greatham plant uses a significant amount of energy at both the front and back end of
its processes used to make titanium dioxide (TiO2) pigments that add brightness,
whiteness and opacity to thousands of consumer products.
Huntsman researchers are developing and implementing new technologies that allow
manufacturing sites to achieve greater energy and raw material savings.
the company developed a new catalyst for producing maleic anhydride that reduces
the amount of butane needed to make the product by as much as four percent.
Huntman’s Performance Products division set a goal to significantly reduce its
energy consumption. Over the past 10 years, the division has reduced its energy
footprint by 13 percent.
In the last five years, the Performance Products division has achieved $9.5 million in
energy savings. In partnership with the U.S. Department of Energy’s Better Plants
Program, the division has achieved a 15.6 percent improvement in energy intensity.
PRODUCT INNOVATION
Energy-saving SPF 50 percent of heating and cooling costs in a typical home are linked to
air infiltration. Sealing a home with spray polyurethane foam (SPF) insulation can save up
to 50 percent in heating and cooling costs. Besides providing exceptional heat resistance,
spray foam based on Huntsman’s technology also retards moisture vapor and provides a
better air barrier. By controlling moisture and air movement through the building
envelope, SPF can improve building durability and indoor air quality.
Algae-based spray foam Researchers intend for the second generation of the product to be
based on algae, which can be grown anywhere. This would eliminate the use of a food
source like soybean and palm kernel. As a member of the Roundtable for Sustainable Palm
Oil (RSPO), an international certification body that promotes responsible management of
palm oil markets, Huntsman is committed to using palm oil conscientiously.
Energy-saving windows and doors TICO PUR Energy-Efficient Window and Door System is
an airtight, wind-resistant frame, which can reduce heat loss by 12 percent to 18 percent
compared to traditional aluminum framing or PVC models with metal stiffeners. The TICO
frame also has better fire performance than PVC and aluminum frames.
Huntsman products are helping the energy industry find and produce more oil and gas.
their surfactants are being used for Enhanced Oil Recovery (EOR), giving new life to older
oil fields and offsetting the need to drill in environmentally sensitive or politically unstable
areas.
Huntsman is working to develop environmentally friendly foamers that aid in EOR. Using
the same biodegradable chemicals found in gentle shampoos, these foamers are designed
to make CO2 more effective in recovering oil in less permeable regions. The foamers enable
drillers to extract more oil out of the ground using less CO2 in the process, which could be a
game changer in making EOR more economical.
DISTRIBUTION
90 percent of all products transported by ship, and 100,000 vessels crossing the ocean each
day, the shipping industry have a major impact on the environment. Huntsman uses 50,000
container ships per year to ship products between various regions.
Huntsman is actively involved in developing a shipping rating system to help the industry
reduce its CO2 footprint. The company has joined with four other major companies to
create the BICEPS Network, which works together with partners from the shipping
industry to support a more sustainable shipping sector.
Huntsman also has a recycling program for packaging materials that reduces the
company’s related carbon footprint by more than 50 percent.
Huntsman contracts with two companies, National Container Group and Industrial
Container Services, to recycle packaging materials. The companies pick up used shipping
containers from customers, clean them and return them to Huntsman for reuse. Last year
Huntsman recycled 45,000 intermediate bulk containers (IBCs), 80,000 55-gallon steel
drums and 40,000 55-gallon plastic drums. As a result, Huntsman avoided 226 tons of
greenhouse gas emissions.
DATA ON PERFORMANCE
TOTAL ENERGY CONSUMPTION-Total energy use in 2015 was just below our 2006
baseline and decreased relative to 2014. Production intensity increased in part
because of lower production levels.
The DyStar Group is a global market leader in colorants, chemicals and services to the
textile industry. Comprehensive range of products and services cater to the individual
needs of customers who include brands, retailers and their industry partners. They also
provide custom chemical manufacturing services for specialty chemicals industries, and
produce a selection of products for the paper and plastic industries. Their history dates
back to 1995, when DyStar was formed as a joint venture between Hoechst AG, Bayer
Textile Dyes, and Mitsubishi. This was followed by another joint venture, five years later,
with BASF AG Textiles Dyes and Mitsui.
The inherited legacy from our early parent companies spans more than a century, reaching
back to some of the first innovations in synthetic dyes chemistry. Over the last decade,
DyStar completed a series of strategic acquisitions to form the core solutions providing
firms in the textile and apparel industry. Organizations that joined our family in that period
include Color Solutions Inc., Yorkshire Americas, The Rotta® Group, The Boehme® Group,
Texanlab and Lenmar Chemical Corporation. 2010 marked a new turning point for DyStar
when we were jointly acquired by the Longsheng Group and Kiri Industries. Today, DyStar
is headquartered in Singapore and supported by a global workforce of over 2,000
dedicated employees.
SUSTAINABILITY STRATEGY
It is widely acknowledged that the textile industry has one of the largest
environmental footprints in the world. Studies estimate that the net carbon
footprint of the average t-shirt is 6 kg, which is about 20 times the weight of the
product itself. Their customers and suppliers face increasing pressure from the
public to behave more sustainably. In keeping with the trends of our industry,
DyStar’s long-term strategy is to continuously innovate, with the goal of mitigating
the adverse environmental, social or economic impacts resulting from our direct
activities as well as the use of our products.
PRODUCTS
DYES, INKS & PIGMENTS
Inks
Reactive dyes
Direct dyes
Vat dyes
Acid dyes
Disperse dyes
Basic dyes
Mordant dyes
Pigments
Denim dyes
AUXILIARIES
Pre-treatment
Dyeing
Coating
Printing
Finishing
Laundry
Spinning and weaving
they reduce the intensity of resource consumption and waste production by 20% . The
new goal applies to production inputs including energy, water and raw materials, as well as
to their corresponding outputs – namely greenhouse gas, waste and wastewater.
Environmental performance is more than a material issue to thier stakeholders.
ENERGY CONSUMPTION
In 2011 they needed almost 10 GJ of electricity, steam and fuel for every ton of product
created.
Today that figure is down 16% to 8.4 GJ per ton production. they manufactured 14% more
product in
2015 compared to 2011 but, in that same period, total non-renewable energy usage went
down by
4.4%, from about 1,266 TJ to 1,210 TJ.
Most energy consumed is used to run plant machinery, IT systems and air conditioning.
Steam is used to
heat chemical and physical processes.
RAW MATERIALS
adopting the core principles of green chemistry, they are continuously optimizing their
manufacturing processes in such a way that chemical yield is maximized and the
generation of waste is minimized.
WATER
The vast majority of water savings are achieved by reusing condensate from purchased
steam. At a number of production sites,they require large quantities of steam and the
resulting condensate is reused for cooling and/or cleaning purposes. Because the cooling
process takes place through indirect heat exchange mechanisms, cooling water remains
uncontaminated by chemical mixtures and can be reused again for other purposes.
Altogether, 21% of their requirement is currently met by reusing water that, to a large
extent, is composed of steam condensate. In 2015 more than 1.7 million m3 of water was
reused.
WASTEWATER
the practice of recovering methanol for reuse in selected processes has secured significant
results. Wastewater reductions derived from this measure totalled to almost 58,000 m3.
Before wastewater leaves any one of dystar properties, they employ a combination of on-
site treatment measures, depending on the physical and chemical nature of wastewater
generated at each production site. Wastewater intended for further treatment at municipal
plants undergo monitoring for all necessary parameters before exiting the premises.
Wastewater destined for final treatment at private third-party treatment plants also
undergo monitoring to ensure that safe limits are not exceeded. At locations where
wastewater is discharged directly to a nearby river body, they take precautions to
minimize the impact to river dependent ecosystems. At the Ludwigshafen Production Plant,
for example, only uncontaminated cooling water is released into the river. Further, to
mitigate any impact on the early-stage development of aquatic species, cooling water is
monitored against high temperatures before exiting the production site. At both the Apiúna
and Corlu Production Plants, cleaning water undergoes onsite treatment and is also closely
monitored before release to ensure that acceptable levels of chemical oxygen demand
(COD) are not exceeded.
Scope 1 emissions from stationary combustion fuels, vehicular fuels, process emissions,
refrigerants and ozone-depleting substances. Among Scope 1 emission sources, natural gas,
alone, accounted for nearly 16.7 thousand tCO2e. Scope 2 emissions, i.e. emissions derived
from purchased electricity and purchased steam, continue to make up the vast proportion
of their footprint. Sources in Scope 2 were responsible for 104.8 thousand tCO2e.
WATER
Gabus Production Plant is one of the rare locations where they
operate in rural surroundings. Since 1995, they provide water to the
neighbouring Indonesian villages of Gabus, Linduk and Sangereng. In
2015, alone, over 34,400 m3 of water was supplied to nearby
communities free of cost. To prevent wastage of planet’s most
valuable natural resource, the Gabus team has also initiated a project
providing faucet valves in parts of the villages where they are
currently not installed.
By applying the principles of green chemistry design, they have been able to develop
products that not only helps to reduce their own impact to the world, but also that of their
customers and end-users. they do not want any substances making their way into their
finished goods . if they are known to be carcinogenic, mutagenic, reprotoxic, bio-
accumulative, persistent, etc.
DYSTAR INDIGO VAT 40% SOLUTION – THE CLEANEST INDIGO ON THE MARKET:
Their core denim product Indigo Vat 40% Solution represents the state-of-the-art in pre-
reduced Indigo liquid, giving customers a cleaner denim production and significant saves
of up to 70% from sodium hydrosulphite consumption.
Indigo is intrinsically insoluble in water and conventional indigo powder must be rendered
water-soluble through chemical reduction with hydrosulphite before it can be used in the
dyeing process. The reduction step is usually carried out manually by exposed dye workers.
With DyStar Indigo Vat 40% Solution, however, reduction is carried out in a closed system
at their production plant; and realized through catalytic hydrogenation, with water being
the key by-product.
Workers do not come in direct contact with the product because it is supplied as a solution
rather than a powder. This also makes it easier to handle safely.
Indigo Vat 40% Solution is a liquid and, hence, does not pose the respiratory risks
associated with a powdered product.
Required chemical input is significantly reduced. Customers also save on the cost for
specialized waste disposal as a result.
digital printing demands tighter drop forming performance, improved stress resistance,
higher color strength, high fastness properties and, of course, reliable eco-performance.
Trouble-free printing.
High color yield.
Top fastness levels on polyester fabrics.
Suitability of inks with various pinheads gives users flexibility.
REALAN® NAVY MF-RRN AND REALAN BLACK MF-PV – NEW, METAL-FREE OPTIONS
IN WOOL DYEING:
Dyestar offers solutions to the biggest segments of the wool market. Customers can
choose from very deep, clear bloom shades designed for high processing and wet
fastness. To achieve a cleaner production for customers, Realan Navy MF-RRN and
Realan Black MF-PV are also free of chrome and other heavy metals. Young children
may be particularly susceptible to the effects of heavy metal exposure but adults are
not immune. Our heavy metals-free chemistry takes into account the safety of our
customers’ employees, the communities that reside near their manufacturing sites
and the final end-user.
SERVICES
ECONFIDENCE
The econfidence program is designed to provide assurance to our customers that
DyStar dyes and chemicals comply with both the statutory and voluntary legal
requirements in the markets they are sold. econfidence is backed up by the most
extensive eco-testing program of any textile chemical supplier. Overseen by a
dedicated and multi-disciplinary team of experts, the econfidence program was
meticulously developed to monitor over 500 restricted chemicals and ensure the
continued reliability of DyStar products. Their customers and direct stakeholders -
in turn - enjoy the comfort and reassurance that their sustainability performance is
not compromised through supply chain activities.
econfidence® is more than DyStar’s responsible sourcing program. It is a
commitment from DyStar toward the ecological quality of its dye and auxiliary
products. econfidence guarantees that all DyStar products are sold in full
compliance with chemical legislations worldwide. This assurance allows
downstream stakeholders to proceed confidently in their business activities. Brands
and retailers who place their trust in econfidence gain multiple benefits:
Confidence in the eco-performance of their textiles and garments
Help in communicating how to meet eco-specifications to their textile production
partners
Shorter lead times and more reliable supply
Support for reputation and brand integrity
Advice on the coloristic consequences of their Restricted Substances List (RSL)
criteria
econfidence hangtags are offered to customers as an effective way for them to
communicate the safety and value of their textiles and garments to potential buyers
Sustainable Textile Solutions (STS) is dedicated to assisting brands, retailers and their
industry partners implement sustainable textile production practices within their
organizations. Their primary goal is to guide clients in the textile industry through the
complex maze of quality and eco-testing requirements, helping them meet all applicable
standards and regulations. STS also provides expertise to customers interested in
operating more efficiently and achieving reductions in cost and resource consumption. The
three main service activities at STS are consultancy, auditing and capacity building. They
tailor our offerings to meet the unique sustainability requirements of every client. The STS
team also supports brands and retailers in their efforts to develop, implement and
communicate their Restricted Substances Lists (RSLs) to existing as well as aspiring
production partners. At the same time, by facilitating compliance with brand and retailer
RSLs, the STS team also assists textile and apparel producers in mitigating their impact on
society and the environment
TEXANLAB
Texanlab Textile and Analytical Laboratory is an ISO 17025 certified, boutique testing
laboratory specialized in ensuring compliance and resolving failures in the customer
supply chain. They are a repository of know-how in ecology testing and analysis for the
textile industry, meeting the requirements of CPSIA, EU Eco-label and brand- or retailer-
defined Restricted Substances Lists (RSLs). Since 1994, Texanlab has tested over 300,000
samples for ecological parameters. Whether handling liquid or fabric samples, Texanlab
applies correct and accurate methods to produce dependable results. We pride ourselves
on a 100% on-time performance record, delivering accurate results in a cost-effective, fast
and reliable manner.DyStar’sTexanlab unit provides accurate and reliable testing services
to guide textile and apparel producers through the complexities of chemical compliance.
They are equipped to meet the most stringent industry testing standards and resolve
failures in the customer supply chain.Texanlab has the capabilities to meet all major brand
and retailer testing requirements. Beyond testing services, they also help textile producers
meet buyer specifications through guidance and training, thus widening the pool of
responsible suppliers for brands and retailers to choose from.
ELIOT
Textile and apparel producers can access eliot via the internet and use the Product Finder
module to identify a dye or auxiliary that meets the requirements of a restricted substances
list (RSL) or a voluntary eco-standard. The Optidye® module lets users explore multiple
parameters to decide on the optimal recipe for their selected product.The sustainable
procurement manager of a brand or retailer aims to comply with the latest chemical eco-
standards. eliot serves as a one-stop center for DyStar’s extensive collection of compliant
dyes and chemicals. For the hands-on procurement professional assisting multiple textile
production partners, eliot serves as a convenient self-service tool that allows users to make
quick and informed product choices.eliot was developed by consolidating different expert
systems and information databases into one comprehensive function for our customers.
The four modules offered on eliot are Positive Lists, Product Finder, Optidye, and
Information. In just one sitting, users can choose from our wide selection of RSL and eco-
standard compliant products using the Positive Lists module, and determine the most
resourceefficient recipe for their selected product via the Optidye module. Its well-
structured user interface makes eliot an intuitive and easy-to-use system for textile
manufacturers. Our responsive design means that eliot can be opened on any computer or
tablet device, and accessed via multiple browsers.
GREEN CHEMISTRY DESIGN
MAXIMIZING THE INCORPORATION OF MATERIAL INPUTS INTO THE FINAL PRODUCT: Economic
pressure has motivated our industry to optimize all processes and eliminate chemicals that
do not end up in the product. Compared to 2011,they need 24% less material for every ton
of production.
USING OR GENERATING SUBSTANCES WITH LITTLE OR NO TOXICITY: They use mainly bromo-
components as intermediates for azo dyes instead of more critical chloro-intermediates.
MINIMIZING THE USE OF SOLVENTS: For health and safety reasons, Dystar uses the safest
solvents and they are recycled where possible. For example, They reuse phenol in the
synthesis of vat dyes and disperse dyes.
IMPROVING ENERGY EFFICIENCY: For efficiency and cost reasons energy input and reaction
time are constantly monitored and optimized. DyStar’s energy intensity has gone down for
the 2nd year in a row.
REDUCING DERIVATION STEPS: They shorten the synthesis chain wherever possible. For
example, the synthesis of Isolan Scarlet K-GLS was recently shortened by one step.
LEVERAGING ON THE POWER OF CATALYSTS: Catalysts are used wherever possible in place of
stoichiometric reagents. In Their production of Indigo Vat 40% Solution, catalytic
hydrogenation is carried out in place of chemical reduction.
DESIGNING FOR DEGRADATION: Persistent chemicals are not used as intentional ingredients
in our production. They go one step further by innovating to create safer chemical
alternatives. DyStar’sEvo® Protect range of durable water repellent (DWR) auxiliaries
makes use of modified fatty acids in place of bio accumulative PFC compounds.
BLUESIGN
DyStar is a system partner of bluesign® and the majority of DyStar products can be found
on the blue finder tool established by bluesign technologies ag. The bluefinder database of
sustainable products contains more than 900 DyStar textile dyes and pigment
preparations; and over 200 DyStar textile auxiliaries. Collection gives manufacturers the
widest selection of products to choose from when producing bluesign approved fabric. In
July of 2015, DyStar participated in the fourth bluesign conference to proudly support the
introduction of blueXpert. The result of a collaboration between Archroma, Huntsman,
DyStar and CHT, bluesign technologies – blueXpert is a revolutionary tool expected to help
the textile industry significantly reduce its environmental impact.
ZDHC
Brands and retailers are under increasing pressure from new regulatory requirements and
NGOs. To meet the demands of their stakeholders, they now require greater chemical
disclosure along their supply chain. Brands and retailers who have committed to the Zero
Discharge of Hazardous Chemicals (ZDHC) goals are intent on eliminating hazardous
chemicals from their supply chains by 2020. DyStar is an active member of the ZDHC
Technical Advisory Committee (TAC). Early on, our Sustainable Textile Solutions (STS)
business unit was instrumental in the development of ZDHC’s audit protocol. DyStar has
long been committed to the highest standards of product safety through its econfidence
program. Hence, the vast majority of our products do not contain, as an intentional
ingredient, any of the chemical groups that are restricted by ZDHC. A comprehensive list of
ZDHC-compliant DyStar products can be accessed via eliot®, new online sustainability
tool.
DYECOO
The DyStar Group and DyeCoo Textile Systems are collaborating on the development of dye
products using DyeCoo’s breakthrough technology of substituting carbon dioxide, also
known as CO2 , for water in the dyeing process. Because water is the medium for most
dyeing processes, wastewater has become one of the chief environmental concerns that
plague our industry. DyeCoo Textile Systems is the world’s first supplier of industrial CO2
dyeing equipment which uses recycled CO2 gas instead of water to permeate textiles with
dyes. Our partnership with DyeCoo will pave the way for more ecological products to meet
the rigorous demands of the industry. This technology offers huge potential to save water
and energy – both of which are top priorities for textile dyers.
SUSTAINABILITY PROJECTS
CONSUMERS
High fastness dyes improve the longevity of clothing so endusers can delay disposal.
Further up the value chain, resources are saved that would otherwise be used to meet the
demand for new pieces. Consumers active in outdoor sports can benefit from water-
repellent jackets without affecting the environment. DyStar’sEvo® Protect range of
auxiliaries uses modified fatty acids in place of persistent PFCs. Mitigating consumer
exposure to carcinogenic, mutagenic and reprotoxic (CMR) substances is pertinent to the
industry, not least because many carcinogens are able to enter the body via skin contact.
When dyes are designed with high fastness properties, colors last longer and consumers
spend less money replacing basic clothing and apparel items over the course of their lives.
Conclusion
It was concluded that the synthetic textile dyes represent a large group of organic
compounds that could have undesirable effects on the environment, and in addition, some
of them can pose risks to humans. The increasing complexity and difficulty in treating
textile wastes has led to a constant search for new methods that are effective and
economically viable. However, up to the present moment, no efficient method capable of
removing both the color and the toxic properties of the dyes released into the environment
has been found.
Reference
www.stitchworld.com
www.dystar.com
www.dystar/sustainability.com
www.huntsman.com
www.hunstam/sustainability.com