Save Water Through Innovations in Textile Industries

1. Introduction

The other name of the water is ‘Live’ or ‘life’. No creature can be alive without water. It is required not only for drinking but also for domestic uses, cleaning, industrial uses, and tree plantations. Its consumption is increasing for the obvious reasons with the increase of all types of creatures, industries, trees, and so on. There will be a tremendous effect on the growth of food and agriculture if the water is found to be limited. Other hand, with the increasing population, residential areas, the water consumption is increasing. How to cope with the total stock of water vs. its growing demand? With the increase in Global Temperatures, the % of vaporisation is increasing, which is affecting the water stock. The study reveals that 70% of the world`s fresh water is used for irrigation purposes (ref: Why Do we need to save water - by Claudette). We are producing about 80% wastewater, which is the product of Industrial, agricultural, and domestic which needs to be filtered for reuse. The study also shows that 62% of the indoor water arrives from domestic uses such as toilets, baths, washing, etc. Hence, it is necessary to adopt the new innovations and technology to save water, to save lives, to grow trees, food, and to maintain hygiene. The researchers predict that half of the world`s half of population will live in water scarcity areas.

Save Water

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2. The Textile Industry Is the Most Water-Consuming and Polluting Industry

The studies conducted in the wet processing Industries indicate that 1 meter of polyester fabric consumes about total of 5000 litres of water throughout the process, and that of Viscose consumes 8000 litres, and cotton consumes 12,000 litres. It generates 20% of global water pollution. (ref: Improving the environmental impact of Dyeing processes, ISCMA). It depends on fabric weight: liquor ratio. Hence, to tackle these challenges to avoid pollution and to consume less water, the following measures are adopted. Please refer to pic 2. (reference Pulcra Chemicals)

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In the standard process, the Dye preparation is done with Detergent and alkali at a temperature up to 100 °C with a duration of 100 mts.
Whereas in the sustainable (sustineri colouring process) process preparation is done with Breviol LGGConc, Foryl SCD, Osimol SCC, with temperature up to 80 °C within 50 mts.
In the standard process, the Dyeing is done with a crease-preventing agent, a wetting agent, a sequestering agent, salt, reactive dyes, at a temperature of 60 °C, and the total time duration is 150 mts, with the addition of Alkali after 120 minutes in the total time duration of 150 mts.
In the sustainable process, the dyeing is done with the addition of Reactive dyes, Salt, and alkali, with a time duration of 50 mts. only at a temperature of 80 °C.
In the Standard Process, after treatment is done with after soaping agent for a time duration of 100 mts, and a temperature of 80 °C.
In the sustainable process, the after treatment is done with Locanit S with a duration of 80 minutes and the temperatures of 90 °C to 40 °C.

Hence, in a summary, it can be said that in the standard process, there is a total number of Baths 9, bath ratio 1:7 (Fig. 2) In the sustainable process, it starts with a neutral medium at 80 °C with new chemical auxiliaries as mentioned. The subsequent soaping is performed at a lower temperature with ringing at 40-50 °C, followed by two baths at 40 °C using new chemical auxiliaries as mentioned, which cause the temperature to drop from 90-95 °C to 40 °C with ringing at PH 4.5- 5 at room temperature. Total number of baths, 5; bath ratio 1:7 (Fig. 2)

[2.1] The Achievements in This New System:

There will be lower consumption of water and energy. Please see Fig. 3
It will reduce the Carbon footprint, hence less pollution
There will be higher production.
Cloth quality will be maintained.

The picture below shows the comparative performances.

Pic – 3

Picture 3 explains the comparative performances in the Sustainable process in energy, Steam, water, and process time. The sustainable process is being experimented with at Pulcra Chemicals, showing very good economic benefits.

3. More Ways to Save Water in the Textile (Dyeing Industries)

To reduce water consumption in the textile industry, several strategies can be implemented, including choosing low-water fabrics, implementing waterless dyeing methods, recycling and reusing water, and adopting advanced water management practices. Waterless dyeing methods, which are known as the dope dyeing process, which is done in the polymerisation stage itself. Reduction in liquor ratio, reducing baths, by reusing the chemicals will save water consumption.
Foam Dyeing and printing is another way to save at least 30% of water consumption. It is done by adding a Foaming agent and a carrier, which yields better colour and water savings.
Many more innovative ideas and technologies are implemented, such as ultrasonic technology by utilising waves for enhanced dye diffusion, microwave technology by applying vibrational energy for optimum colourisation, and electrochemical reduction for vat and sulphur dyes.
Switching from Jet Dyeing to U-Jet saves in water consumption substantially, with lower liquor ratio and higher efficiency with superior uniformity. It is cost-saving too.
To implement automatic controls for ringing with the spray ringing techniques.
Waterless dyeing, like solvent Dyeing or Plasma Dyeing, saves water from the conventional process.
By implementing the reuse of water systems and treating and reusing wastewater for various purposes within the production process, like cooling or cleaning.
To see the chances of exploring ZLD (zero liquid discharge) systems, which can recover a high percentage of water used in textile operations, making it suitable for reuse
To emphasise Organic Cotton and other sustainably produced fibres, which require less water during production.
Please have the system of Rainwater harvesting system and to procure it.
To check all the equipment in the wet processing unit so that no water/steam leakage, no overflow of the baths, etc.

4. Conclusion

Save water, it is precise; such awareness must be brought among the consumers.
In the wet processing system, several measures can be adopted to save water, such as reducing baths. The temperature and time duration can be reduced by adding auxiliaries, which gives savings in energy too.
Recycling, reuse are obviously the traditional methods.
Reducing the liquor ratio also saves water.
Foam dyeing printing is another way to save water.
To switch over from Jet Dyeing to U-Jet can save water substantially.
Waterless dyeing, or Dope dyeing, is a method of saving water.
To procure Rainwater harvesting to save water.