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Denim Factory Tales

Quality and sustainability at Echotex state-of-the-art denim plant

Echotex is one of the largest fully vertical set up green factory in Bangladesh that achieved LEED platinum certification for their sustainable commitment. With a firm promise of continuously striving to produce the best quality product in a sustainable way.

Echotex denim plant
Figure 1: Echotex achieved LEED platinum certification for their sustainable commitment. Courtesy: Echotex

Anywhere in the world, denim is a craze word and this popularity has given the Bangladeshi apparel manufacturers a golden chance. The second-largest apparel producer and exporter in the world, Bangladesh has 31 denim mills with a capacity of a staggering 435 million yards of fabric a year. In addition, Bangladesh proudly supplies a lion share both in the US and EU market. Bangladesh is one of the largest exporting countries of denim products to Europe with a 27% market share.

Seizing this opportunity, in 2017, Echotex invested for denim with 12 lines sewing capacity of 20,000 pieces per day. Equipped with state-of-the-art environment-friendly machinery, Echotex denim plant washing facility – washing capacity is 20,000 pieces per day – saves 60-70% water.

Echotex denim plant sustainability story

Redwan R. Chowdhury Director (HR & Ethical Trades) shared, “When our management thought to expand business in a new way, we decided to invest in denim. Because of our 90-line knit production has a seasonal effect, but denim products demand is recurrently growing in the global market which has no seasonal impact.”

Echotex denim plant is capable of enzyme, bleach, stone wash, scraping, laser, PP, whisker, 3D crinkle, ozone, etc. The company installed Jeanologia laser machine and ozone generator machine for Ozon (waterless) finish. They also have Italy originated Tonello UP system washing machine for saving water and no stone is required. Triveneta dryer machine from Italy with 10,000 pcs/day capacity.

Echotex installed automatic stitching in the sewing line. Automatic sewing machines deliver top-notch professional results in the shortest possible time, increasing productivity and saves energy.

Another marvelous technique Echotex uses to reduce natural gas consumption by installing condensation traps and condensate is collected and transferred to the boiler feed tank, which increases boiler feed tank temperature and reduces natural gas consumption in its washing, finishing, dyeing and garments ironing section.

Echotex working environment
Figure 2: Echotex provides sustainable working environment. Courtesy: Echotex

The whole facility is equipped with LED and energy-saving lights which consumes 60% less electricity i.e. dyeing, finishing, washing, printing, garments and utility buildings which contributes to save 512,960 Kw/yr.

“One of the challenges for Bangladesh is adding value to denim products through design development and innovation. In this regard, the sector currently needs more investment in research and innovation to meet the goal,” emphasized Uzzal Dakua, Merchandising Manager, Echotex Ltd.

By 2021, they have a target to expand 24 lines after analyzing the annual turnover of the company.

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