Robintex Group introduced cold pad batch dyeing (CPB) dyeing in 2018 in Bangladesh for the first time. As of 24 September 2021, it dyed a total of 7.132 million kg of knit fabrics in a continuous system.
On average the company saved a total of 30 liters per kg in this production process. In this way, Robintex Group was able to save around 213.96 million liters of water.
Robintex’s Cold pad batch dyeing system achieves 13% carbon savings and over 50% water savings in fabric manufacturing compared with conventional exhaust dyeing.
In addition, it did not require any salt to run the production. Salt especially is a crucial factor for water pollution and increases the running costs of ETPs. Since the inception of Robintex’s project, it has avoided the use of approximately 1430 tons of salt.
As Robintex dyed at 25-degree room temperature which saved a total of 64 million kg of steam.
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.
Robintex is using an ERBATECH machine from Germany which runs on average 40m/min and is user-friendly. This padder has Nip dyeing system, so the tailing problem is eliminated. In the nip pad, dyes are picked up instantly. Eliminating the 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 a 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.
The CPB procedure is simple since the only step involved 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 chemicals. It also has the capability of continuous production. The reduced dyeing auxiliary concentration leads to minimizing the waste effluent. The alternative dyeing methods to CPB like the exhaust method are expensive due to the requirement of thermal energy for dye fixation.
Robintex’s most advanced and dynamic ERP-backed inherent system figures out the most efficient economy of scale in which cost optimization, timely delivery, the global standard, appropriate technology, skilled human resource and all together, the maximum benefits to the valued customers head for the optimal harmony.