Each drop counts

Chemical solutions for

reduced water consumption
NEWS CHAT

NEWS CHAT is Clariants publication dedicated to

introducing chemical solutions to the textile industry.

As a global leader in specialty

chemicals and dyes, Clariants
Textile Chemicals Business Unit
is committed to establishing
long-lasting customer relationships based on our proven
expertise, innovation and
sustainability.

Customers prefer to work

with us because we identify
their needs early on and provide
outstanding, customized
products along the entire
textile processing chain.

We boost our customers

creativity and efficiency with
creative solutions that add
value to their own products
and services with a strong focus
on sustainability combining
profitable growth with social and
environmental responsibility.
Wherever you are and whatever
you do, Clariant is always

Close to you!
2

NEWS CHAT

Come and meet our specialists at upcoming trade shows.

UPCOMING Events

17-19 April 2013

CHINA INTERDYE 2013

Shanghai, China

18-21 April 2013

INDO-INTERTEX 2013
Hall A, booth A 105
Jakarta , Indonesia

22-23 May 2013

DENIM BY PREMIERE
VISION 2013
Paris, France

11-13 June 2013

TECHTEXTIL 2013
Hall 3.0, booth B 33
Frankfurt am Main, Germany

Chemical technology
for a better tomorrow

ADDRESSING WATER
SCARCITY

Global awareness about water scarcity

has considerably increased in recent
years among the general public, with
actions conducted by NGOs or inter
national institutions such as the United
Nations with the World Water Day on
22 March 2013.

With its DETOX campaign started in July 2011, Greenpeace has

brought the topic to the attention of consumers, notably leading
major apparel brands and retailers to commit to the so-called
Joint Roadmap to Zero Discharge of Hazardous Chemicals.
Reducing water pollution is of course one area of action, and
Clariant is playing its part with our constant stream of dyes and
chemicals innovations.

Governments are closely monitoring the situation. Water scarcity

and, as a consequence, water pollution have shown dramatic
consequences for local populations in production countries, such
as China and India. Authorities in those countries are taking
strict measures to ensure cleaner production by local textile
mills or laundries, such as water treatment facilities or setting
tight load limits in water effluents.

But a lot can be done in water consumption per se. Major apparel
and outdoor brands and retailers are showing strong interest in
processes and solutions that allow tackling the problem at its
source: reducing water consumption during textile production.
Clariant, with our firm commitment towards sustainability
by innovation, has introduced in recent years a number of
innovative solutions that can be easily adopted by textile mills
and manufacturers willing to answer the growing demands for
reduced water consumption by brands and retailers.
And with our new ONE WAY sustainability service launched
in October 2012, Clariant can help textile mills demonstrate,
with transparent and reliable facts and measurements in hands,
how new available technologies help answer the brands and
retailers requirements for more sustainability at controlled
cost levels.
Read through the following pages to discover our chemical
solutions for reduced water consumption because each drop
counts.

NEWS CHAT

Less is more More colors

with less water in denim dyeing
ADVANCED DENIM

The production of denim

fabric usually involves huge
quantities of water. This is a
problem Clariant practically
solves with its groundbreaking
Advanced Denim technology,
which simplifies the finishing
and dyeing of a fabric that
accounts for some 14%
of global cotton production.

But there is more. For over a century, the

principle dyes used in the production of
standard blue denims were indigo based,
which restricted the palette of colors available
to manufacturers. Clariant sets a new
benchmark with its Diresul RDT Indicolor
dyes, opening the door to an infinite range of
shades and hues: arctic night, blue sky, dark
sea, earthy tones, greens and a full range of
colors inspired by and created for nature.
Together with blues, navies, grays and blacks,
they enhance denims look and feel, add a
vast range of new shades and wash-down
effects, and create smart finishes.

When it comes to environmental compatibility
Clariants trail blazing new technology
raises the bar to a whole new level

Based on Clariants Denim-Ox and Pad/Sizing Ox, the two core innovative
processes introduced under our Advanced Denim concept, the idea consists of
replacing indigo dyes with Diresul RDT sulfur dyes in the dyeing process in
combination with Arkofil DEN-FIX sizing agents. The Advanced Denim dyeing
processes can cut the number of dyeing vats from 15 in conventional indigo-based
dyeing down to 1 (one!).
In total, when employing the Clariants Advanced Denim processes, Denim-Ox
and Pad/Sizing Ox, water consumption can be reduced by up to 92%, while up
to 63% of the usual cotton waste can be avoided. Plus, up to 30% can be saved in
energy costs compared to traditional denim processes.
6

NEWS CHAT

Savings Potential

The use of Clariants Advanced

Denim technology allowed savings
of ~ 700 million liters of water in
2012. Clariants Advanced Denim
was used only in an extremely
small part of the worldwide
production of jeans. Imagine how
much water could be saved if
more manufacturers joined the
Advanced Denim revolution!

conventional indigo dyeing Vs. Clariants

Pad/Sizing Ox (front line)

Colors other than blue have been in the past trickier to achieve
but with Diresul RDT dyes in combination with the Denim-Ox
and Pad/Sizing Ox processes used in the Advanced Denim
technology, it is much easier. The process is simple to control,
more efficient and suitable for small batches. Advanced Denim
makes it very simple to rapidly respond to changing demands
from the market. Clariants full range of Diresul RDT sulfur
dyes allow unique effects, better reproducibility of tones and
shades as well as more precise results to be achieved without
making any changes to existing production lines.

Awarded technology, certied environmental benets

Advanced Denim technology has been honored by two of the prestigious 2012
Innovation Awards organized by ICIS Chemical Business magazine. Not only was
the Advanced Denim breakthrough eco-advanced dyeing technology recognized
by the jury as Innovation with Best Environmental Benefit, but it was also judged
as the years overall winner.

Compared with conventional denim production, Clariants

unmatched Advanced Denim technology is simpler, more
versatile, and opens the doorway to undreamt-of opportunities.
And when it comes to environmental compatibility, Clariants
trail-blazing new technology raises the bar to a whole new level.

In addition, Clariant was one of the first companies to be awarded an EU Ecolabel*

for its illustration collection of jeans in recognition with the sustainability benefits
of Advanced Denim. The EU Ecolabel, also known as the EU Flower label,
is considered one of the highest certifications, acknowledging that all stages in
the production of a finished article have met the EUs stringent environmental
protocols.
Additional information can be found at: www.advanceddenim.clariant.com

ClARIANTS ONE WAY SCORE CARD

Clariants Advanced Denim process, compared to conventional process

-92%

Water
consumption

-25%
Time

-45%

Energy
consumption

0.14

Process
BOD/COD

-26%

CO2
emissions

Read more about ONE WAY on http://textiles.clariant.com

8

NEWS CHAT

Tease your thirst for innovation;

quench your process thirst for water
ClARIANTS SWIFT CONTINUOUS
DYEING PROCESS FOR PES/CEl

ClARIANT HElPS ACHIEvE CONSIDERAblE WATER SAvINGS WITH ITS SWIFT PROCESS

Continuous dyeing of polyester/cellulose (PES/CEL) woven

fabrics is another example of a process that can be extremely
resource intensive. Established methods for dyeing such blends
require high amounts of water, as well as energy and chemicals.

ClARIANTS ONE WAY SCORE CARD

Clariants SWIFT continuous dyeing process for PES/CEL, compared to conventional process

Clariant therefore developed the new so-called SWIFT

continuous dyeing process for PES/CEL blends using the
innovative Foron S-WF disperse dyes together with the high
performing Drimaren HF-CD specialty reactive dyes for
continuous application. A little bit of Clariants SWIFT process
for dyeing PES/CEL woven fabrics represents a lot: an innovative
solution for dyeing all depths of shades, which minimizes the
environmental impact by meeting industry demands for shorter
and economical processes that save water and energy.

-50%

Water
consumption

-50%
Time

-45%

Energy
consumption

-25%

Chemical
usage in
volume

> 0.1

BOD/COD
Ratio

-45%

CO2
emissions

Read more about ONE WAY on http://textiles.clariant.com

10

NEWS CHAT

11

Conventional process is highly intensive

on water and other resources.

SWIFT process allows considerable

water savings.

In the established process for continuous dyeing PES/CEL fabric, This reduction clearing step
means that the fabric must be
a polyester/cellulose fabric is most commonly dyed using a
combination of either disperse/vat dyes or disperse/reactive dyes. passed twice through the
continuous dyeing range.
The polyester portion of the blend is dyed with disperse dyes by a This has a high impact on
pad-dry-thermosol procedure, whereas the cotton portion is dyed energy and water consumption
together with productivity,
with either vat or reactive dyes by a chemical pad steam process.
labor and effluent treatment
costs.
In the case of vat dyes, a reductive steaming (caustic/hydros)
1
step
is
necessary
to
convert
the
dye
to
its
soluble
form
so
that
it
bal Product
Paul Catlow,
Marketing
Textile
Cellulosic
Chemicals,
Dyes,
Global
18.01.2013
Product Marketing Cellulosic Dyes, 18.01.2013
can diffuse inside the cotton fiber. At the same time, this acts as
a reduction clearing process by removing any unfixed disperse
dye from the polyester fiber surface, ensuring that a high fastness
level is achieved.
1

Paul Catlow, Textile Chemicals, Global Product Marketing Cellulosic Dyes, 18.01.2013

Steam
-Dry / Thermosol
Pre-Dry / Thermosol
Pre-Dry / Thermosol

Pre-Dry / Thermosol

Steam
Steam

Steam

A one-bath, two-stage process for dyeing PES/CEL with alkali

clearable Foron S-WF disperse and Drimaren HF reactive dyes
where high wash fastness is achieved without a reduction
clearing step.
The disperse and reactive dyes are padded together, and the
whole process can be completed with one pass through a
continuous dyeing range. The SWIFT continuous dyeing process
for PES/CEL can dye fabrics at all depths of shade, reducing
water and energy consumption while increasing productivity.

Paul Catlow, Textile Chemicals, Global Product Marketing Cellulosic Dyes, 18.01.2013

Pre-Dry / Thermosol
Pre-Dry / Thermosol

Steam
Steam

Paul Catlow, Textile Chemicals, Global Product Marketing Cellulosic Dyes, 18.01.2013

Pad
PadNaOH
NaOH
Hydros & Hydros
Wash Off
Off
Pad
Pad NaOH &Pad
Hydros
Pad&&NaOH
WashWash
Off
Pad
Hydros
disperse
dye clear)
(reduction
clear)
disperse
(reduction
(reduction
clear)
(reduction
clear)
disperse
dyedye

Pre-Dry

Pre-Dry

Pre-Dry
Pre-Dry
Steam
Pre-Dry / Thermosol

12

Pre-Dry

Dry

Pad
NaOH
& Hydros
PAD
FORON S-WF & Pad
Pad
NaOH
& salt
disperse dye
(reduction clear)
DRIMAREN HF DYE

Steam
Steam
Steam

Pad
Pad NaOH & Salt
reactive dye
Pad
Pad
NaOH && Hydros
Pad
Pad NaOH
Salt
Pad Pad
Salt Pad
disperse
dyeNaOH &
(reduction
clear)NaOH
REACTIVE DYE

reactive dye

Dry Off
Dry
Wash
Dry

Pre-Dry

Steam

Steam

Wash Off
Off
Salt
WashWash
Off

Dry
Dry
Dry
Dry
Wash

Pad
reactive dye

Off

NEWS CHAT

Dry

Pad NaOH & Salt

Dry
Dry

Savings Potential

Steam
Wash Off

&

Wash Off
Off
Wash

Wash Off

The swift process allows up to

50% water savings compared to
conventional continuous dyeing
Dry
process for PES/CEL fabrics using
disperse and reactive dyes.

13

Lets pour water in a glass,

not in a tee-shirt

ULTRA LOW LIQUOR RATIO

CELLULOSIC DYEING

In the past few years, new types of jet dyeing machines have been introduced
which can dye cotton at an ultra low liquor ratio (ULLR) of 4:1 6:1. For cotton
processing, the liquor ratio can be reduced from 8:1 to 4:1, allowing reduced
fabric tension and friction for better fabric running conditions in the chamber,
shorter processing times (e.g. faster loading/unloading, heating/cooling, filling/
draining) and reduced water, energy and chemical consumption.
Add to that the right dyes, Clariants Drimaren HF range, and textile
manufacturers are in the position to achieve vast savings in water, energy
and chemical consumption, and reduce the environmental footprint of the
textile produced.

Clariants drimaren hf range allows manufacturers
to achieve vast savings in water

Preparation, dyeing and finishing of cotton

substrates have utmost water, energy and chemical
requirements and therefore offer high possibilities
for savings. Reduction in the amount of water used
is a particular focus because it brings corresponding
reductions in the energy required to heat water
and, to a lesser extent, the amount of dyes and
chemicals used.
14

NEWS CHAT

When dyeing at low liquor ratio, Clariants Drimaren HF

reactive dyes display high neutral substantivity combined with
very good migration/leveling in the salt phase and a high degree
of fixation close to the exhaustion value after the alkaline step
guarantees high shade reproducibility. Lower salt requirements
help save water as the number of rinsing baths can be reduced.
And the low substantivity of the unfixed dye, combined with very
good diffusion, guarantees optimum washing off performance.
This saves time and energy as high wet fastness is achieved after
only four rinsing baths at a temperature of 60C.

Savings Potential

With Clariants Drimaren HF

reactive dyes used in ultra low
liquor ratio dyeing process, water
consumption can be reduced by 25%
compared to traditional processes.

15

bENCHMARK DYEING AND WASHING OFF PROCESS FOR REACTIvE DYES

(EXHAUST WARM)
(C)

(C)

100

100

90

90

80

80

70

70

45 60 min

60

30 45 min

60

50

50

40

40

30

30

20 0

20 0

A:

DYEING AND WASHING OFF PROCESS FOR DRIMAREN HF REACTIvE DYES:

ISOTHERMAl 60C

x
2.0
1.0
1.0

20
b

40

60

80

100

120

140

g/l Common or Glauber`s salt

g/l Ladiquest 1097 liq
g/l Imacol C3G liq
g/l Humectol C liq hc

160

180
D

b:
C:
D:
E:

200
E

220

240

260

280

300

320

340

Reactive dye (linear metering)

Soda ash (linear metering)
Neutralization (pH 6-7)
1.0 g/l Ladipur RSK liq

A:

x
2.0
1.0
1.0

20
b

40

60

80

100

120

140

g/l Common or Glauber`s salt

g/l Ladiquest 1097 liq
g/l Imacol C3G liq
g/l Humectol C liq hc

160
D

b:
C:
D:
E:

180

200

220

240

260

280

300

320

340

Drimaren HF dye (linear metering)

Soda ash (linear metering)
1.0 g/l Ladiquest 1097 liq
1.0 g/l Ladipur RSK liq
Neutralization (pH 6-7)

ClARIANTS ONE WAY SCORE CARD

Clariants Drimaren HF reactive dyes used in ultra low liquor ratio dyeing process, compared to benchmark process

WASHING OFF PROCEDURE AT 60C

Washing off procedure at LR 6:1.

Bleached Cotton Interlock (2320).
Rinsing Bath 1= 10 min at 60C.
Rinsing Bath 2= 10 min at 60C.
Rinsing Bath 3= 10 min at 60C + 1g/l Ladipur RSK liq.
Rinsing Bath 4= 10 min at 60C + neutralization to pH 6-7.

-25%

Water
consumption

-33%
Time

-43%

Energy
consumption

-2.5%

Chemical
usage in
volume

> 0.1

BOD/COD
Ratio

-32%

CO2
emissions

Read more about ONE WAY on http://textiles.clariant.com

16

NEWS CHAT

17

Water savings with all-in-one

solution Its magic

BLUE MAGIC FOR DISCONTINUOUS

PRETREATMENT

Clariants all-in-one bleaching auxiliary is the key to the new

BLUE MAGIC process. Based on Imerol BLUE liq, it generates
both economic and ecological advantages. Besides its advanced
brightening effect, BLUE MAGIC provides higher productivity,
simplified handling, better uniformity and improved dye-ability,
with less impact on the environment.
Imerol BLUE liq is a wizard with a hat full of fantastic magic tools.
One single product delivers an efficient, economic and short
discontinuous pretreatment. Whether you need a ready-for-dyeing
grade or the brighter optical white, the BLUE MAGIC process will
deliver it, without a separate rinsing, resulting not only in shorter
time and reduced energy, but also in reduced water consumption.

From yarn to cotton flocks, to terry towels,

woven and knitwear, the BLUE MAGIC process
can allow savings up to 50% in water, 40% in
energy and 50% in time.

18

NEWS CHAT

Savings Potential

Clariants BLUE MAGIC can allow

savings up to 50% in water. It is so
simple that it seems like magic!

19

ClASSICAl blEACHING PROCESS

blUE MAGIC PROCESS

TEMPERATURE (C)

TEMPERATURE (C)

120

120

30 min at 95 C

100

max.

15 min at 110 C

100

10'
80

80

Drain

Drain

Dyeing

10'
60

60

15'

15'

Acid neutralization
40
20
0

Wetting Agent/detergent Stabilizer

NaOH+H2O2
20

40

60

20

80

100

120

The combination of the exceptional properties of Imerol BLUE liq, based on

the Singulet Bleaching Technology, opens new doors for the exhaust bleaching
world. BLUE MAGIC can be used in all the different forms of discontinuous
pretreatment.
The combination of Imerol BLUE liq and optical brighteners achieves the
highest degree of whiteness. Either in one step for high whiteness or in two steps
for the brightest optical white, the BLUE MAGIC process will dazzle you.

TIME (MIN)

Savings up to 1 hour

Bactosol SAP liq c

Sirrix NE liq

40

Catalase

Dyeing

Imerol Blue liq

NaOH+H2O2
20

40

60

80

100

120

TIME (MIN)

ClARIANTS ONE WAY SCORE CARD

Clariants Blue Magic all-in-one bleaching process with Imerol Blue, compared to benchmark process

-21%

Water
consumption

-35%
Time

-28%

Energy
consumption

-2.5%

Chemical
usage in
volume

0.2

BOD/COD
Ratio

-29%

CO2
emissions

Read more about ONE WAY on http://textiles.clariant.com

20

NEWS CHAT

21

Walking the walk

CLARIANTS SUSTAINABLE
EFFLUENT TREATMENT
FACILITY IN PAKISTAN

Clariant does not only focus on developing water

saving solutions for its customers; we also take at
heart to reduce our own impact on water usage.
In May 2012, Clariant started operating what we
believe is the first-ever sustainable effluent
treatment (SET) facility for a textile operational
site in Jamshoro, Pakistan.

The Jamshoro site is one of the biggest textile

chemical sites within Clariant. It produces dyes,
chemicals, emulsions and pigment dispersions.
The SET facility is a clear sign that we are
constantly aiming for ever more sustainable
solutions.

The operational SET plant is spread over an

area of 25 acres consisting of primary, secondary
and tertiary treatment to yield colorless water
with a COD (Chemical Oxygen Demand) less
than 75 ppm, BOD (Biological Oxygen Demand)
below 20 ppm and TDS (Total Dissolved Solids)
below 250 ppm.

Savings Potential

Water Consumption per Kg of Product

With an investment of USD4.0 million, the SET facility not only

supports the substantial saving of 80 percent of water by
recycling and reusing, but also allows effluent treatment based
on zero liquid discharge fulfilling the very stringent Pakistans
National Environmental Quality Standards (NEQS) requirements.
The Clariants SET facility allows savings of 240 million
liters of water per annum.

30

30

24

25
20
15
10
5
0

5.6
1.4

dyes

chemical

2.8 2.24 0.56

emulsion

Waste water treatment

SET treatment
Water saved in ltr.

Dyes, chemicals, emulsions and pigment dispersion manufactured
at the plant are produced using the SET facility

22

NEWS CHAT

23

WWW.TEXTILES.CLARIANT.COM
TEXTILE.CHEMICALS@CLARIANT.COM
Clariant International Ltd

Rothausstrasse 61
4132 Muttenz
Switzerland
BUSINESS UNIT TEXTILE CHEMICALS

This information corresponds to the present state of our knowledge and is

intended as a general description of our products and their possible applications.
Clariant makes no warranties, express or implied, as to the informations
accuracy, adequacy, sufficiency or freedom from defect and assumes no liability
in connection with any use of this information. Any user of this product is
responsible for determining the suitability of Clariants products for its
particular application. *Nothing included in this information waives any of
Clariants General Terms and Conditions of Sale, which control unless it agrees
otherwise in writing. Any existing intellectual/industrial property rights must
be observed. Due to possible changes in our products and applicable national
and international regulations and laws, the status of our products could change.
Material Safety Data Sheets providing safety precautions, that should be
observed when handling or storing Clariant products, are available upon request
and are provided in compliance with applicable law. You should obtain and
review the applicable Material Safety Data Sheet information before handling
any of these products. For additional information, please contact Clariant.
*For sales to customers located within the United States and Canada the
following applies in addition
No express or implied warranty is made of the merchantability, suitability,
fitness for a particular purpose or otherwise of any product or service.
Trademark of Clariant registered in many countries
* Certificate number: ES-CA/016/007
2013 Clariant International Ltd

SAP 1104603, EN, 3.2013

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