Cold Pad Batch dyeing technology achieves 13% carbon savings and over 50% water savings in fabric manufacturing compared with the conventional exhaust dyeing.
Ecological sustainability demands are constantly rising, especially with regard to the consumption of water and energy. Cold Pad Batch (CPB) dyeing is one of the most economical and environmentally friendly approaches in the textile industry. With the vision of cleaner production and sustainability, a Bangladesh-Germany joint venture factory Robintex Group introduced CPB dyeing in Bangladesh for the first time. They started CPB in mass production from 2017 in Narayangonj factory.
Robintex placed its stenter, straighter, compactor and all other dyeing finishing machines from Germany. Foreign experts help maintain the groups dyeing standards and develop its local expertise as well. It has the most contemporary sample dyeing machine also.
Many methods are used for dyeing cotton with reactive dyes, but the CPB method is relatively more environment-friendly due to high dye fixation and non-requirement of thermal energy owing to low bath ratio (M: L = 1:1) required for the process. It is a widely used technique for the semi-continuous dyeing process.
Engr. Muhammad Mahiuddin, Executive Vice President of Robintex Group said, “Environmental responsibility is best achieved in cold pad-batch application since no salt and steam is required, the rate of dye fixation is at ambient temperature is high. It’s also a cost-effective process with a very high level of reproducibility.”
Robintex is using ERBATECH machine from Germany which runs on average 40m/min and user-friendly. ERBATECH padder has Nip dyeing system, so tailing problem is eliminated. Their production capacity is 20 ton per day. They are using nip pad where dyes are picked up instantly. There has no chance for hydrolyzed. A uniform dye quality is achieved with even color absorbency and colorfastness. In pad batch dyeing, qualities like high shade reliability and repeatability are common. This is because of the high reactivity of dyes with rapid fixation rate and stability.
In the pretreatment process, Robintex is using the singeing process instead of bio polishing from a sustainability aspect. Because bio polishing requires a huge amount of water and chemicals and finally decreases the strength of the fabric. At the same time, they practice drying and finishing on stenter machine to eliminate the process.
Behind the story of a successful pioneer, Muhammad Mahiuddin shared, “We are using the same type of machinery for pre-treatment, dyeing, and washing for a continuous process. Our machine and chemical suppliers have supported us during the installation. It must require to be the same nature of all dyeing process, otherwise, perfect dyeing couldn’t be achieved. Some factories installed machinery before us but they did not take the risk of mass production. In here, now we are the successful pioneer of CPB dyeing.”
A report showing that Cold Pad Batch dyeing technology achieves 13% carbon savings and over 50% water savings in fabric manufacturing compared with the conventional processes using exhaust dyeing.
The CPB procedure is simple since the only step involved in the passage of fabric through the dye bath and squeezing through the dyeing padder with subsequent batching for twelve hours.
Compared to traditional exhaust dyeing methodology, CPB dyeing technology consumes less water, energy, and chemical. It also has the capability of continuous production. The reduced dyeing auxiliary concentration leads to minimize the waste effluent. The alternative dyeing methods to CPB like exhaust method are expensive due to the requirement of thermal energy for dye fixation.
Environmental responsibility is best achieved in cold pad-batch application since no salt and steam is required.
“I believed that improved environmental impact, resource efficiency savings and the higher quality of CPB-dyed fabric present a strong alternative than the conventional exhaust dyeing. Where salt in the effluent is an issue CPB dyeing should be the method of choice, hence less TDS in ETP. These benefits contribute to the sustainable development of the entire textile industry,” Mahiuddin further added.
Robintex has been awarded “The best works friendly knit factory” by the government of Bangladesh. It’s most advanced and dynamic ERP backed inherent system figures out the most efficient economy of scale in which cost optimization, timely delivery, global standard, appropriate technology, skilled human resource and all together, the maximum benefits to the valued customers head for the optimal harmony.