Nike has opened its first water-free facility, which will end the use of water and process chemicals from fabric dyeing at its Taiwanese contract manufacturer Far Eastern New Century.
The process, which Nike has dubbed ColorDry, reduces dyeing time by 40 percent, energy use by about 60 percent and the required factory footprint by 25 percent compared to traditional methods, the company says. ColorDry products will be introduced to the marketplace in early 2014
The process, which Nike has dubbed ColorDry, reduces dyeing time by 40 percent, energy use by about 60 percent and the required factory footprint by 25 percent compared to traditional methods, the company says.
The processes developed by AirDye, ColorZen and DyeCoo - the latter's process is being used by Adidas - differ greatly, but their results are similar: water use is cut to near zero sharply cutting pollution, the quantity of chemicals used is greatly reduced and faster drying cycles cut energy consumption.
According to Kobori, the waterless jeans are as good for the environment as they are for Levi's bottom line - they cost less to produce than a standard pair because they consume less water and energy. In 2014, Levi's saved an estimated $1.6 million in costs of goods sold from the program.
Dye houses in India and China are notorious for not only exhausting local water
supplies, but for dumping untreated wastewater into local streams and rivers.
cotton and polyester, the two most mass marketed textiles
Waterless dyeing should be the textile industry's holy grail
Cotton comprises 45% of all fibres used within the global textile industry, so a
sharp reduction in water consumption would be a huge process improvement for
this sector.
Its process modifies cotton's molecular structure and allows dye to settle
within the fibres without requiring the massive discharge of water,
lasts
can finish cotton fabric using 90% less water and 75% less energy.
AirDye
a sliver of the water and energy compared to traditional dyeing processes,
Instead of water, the company's technology uses air to disperse dye
polyester is the prime candidate because dyeing performs best in an airless
environment with pressurised high hea
r and is more resilient to chemicals and washings.
Nike identified water inadequacy and resource cost volatility among the risks, opportunities and challenges surrounding its business. This became the driving force behind the forging of the relationship between Nike and Dutch award-winning startup DyeCoo, a Dutch company that launched the world's first ever industrial dyeing machine that uses high pressure carbon dioxide (CO2) as a replacement for water to dye polyester.