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Sedo Engineering brings eco-friendly Smart Indigo™ technology for denim industry

Usually, blue jeans are dyed with indigo for its fashion DNA that is insoluble in water and therefore cannot be used directly for dyeing. The processes used today consume a tremendous amount of chemicals, which pollute the environment. This high environmental burden should be stopped now. Smart-Indigo™ dyeing developed by Sedo Engineering will significantly reduce the ecological footprint by using electricity instead of chemicals.

Sedo Engineering has developed Smart-Indigo™, a groundbreaking technique, which revolutionizes the Indigo dyeing process. This environmentally friendly process gives greater efficiency and savings in time and costs. Utilizing electro-chemical techniques, Smart-Indigo™ produces industrial scale “leuco” Indigo on demand.

Sedo Engineering brings eco-friendly Smart Indigo™ technology for denim industry
Figure 1: Manfred Mentges (Right), Sales Director, Sedo Engineering; S M Al-Masud, Managing Director, S M Engineering; Herbert Guebeli, General Manager, Sedo Engineering.

Why Smart-Indigo™

Every year over 15 billion meters of denim fabric are produced globally. Most of the production takes place in countries like China, India, Pakistan, Mexico, Brazil, Europe, Turkey, Middle East, USA, and Canada.

Denim fabric production worldwide
Figure 2: Denim fabric production worldwide.

The demand for denim continues to grow. 66,000 tons of indigo powder is needed to produce 15 billion meters of denim fabrics to different shades of blue. The famous blue indigo is a powder, which needs hazardous chemicals to make it water soluble for the dyeing process. After dyeing, tons of wastewater containing these chemicals are discharged into the environment often without treatment. So, the denim industry needs an urgent solution to terminate or reduce this major pollution problem.

Production of Leuco-Indigo

As a tremendous solution of denim dyeing, “Smart Leuco-Indigo” is produced in an electrochemical process consuming considerably fewer resources than existing methods, using only-

  1. Indigo pigment
  2. Caustic soda
  3. Water and
  4. Electricity

Production of Leuco-Indigo

In a fully automated process, the clean Leuco-Indigo is produced, metered and fed directly to the dye bath. The Smart-Indigo™ solution is the most sustainable way to dye denim.

Chemical equation:

Indigo + 2 e- + 2 Na+ = à Leuco-Indigo

2 NaOH – 2 e- = à 0.5 O2 + H2O + 2 Na+

The first machine is successfully in full production since last 1.5 years at Italdenim, Inveruno near Milan, Italy.

Three dimentional carbon electrode

Here in the figure-

  1. Feeder electrode
  2. Bed of particles
  3. Cathodic compartment
  4. Grid
  5. Anode
  6. Anodic compartment
  7. Cationic exchange membrane

Revolutionary Leuco-Indigo process opens up a whole new range of opportunities-

  • High sustainability
  • Reduced health hazards
  • More ecological and economical
  • Better color consistency and performance
  • Easy to handle and more efficient

Comparison of environmental impact

Using electricity instead of chemicals in Smart-Indigo™ dyeing process significantly reduces the environmental pollution and energy consumption.

  • Less chemically contaminated wastewater
  • Reduce the cost of ETP
  • 6 times reduce energy consumption
  • 10 times less carbon footprint
  • No transportation ways

6 times less CO2 in smart indigo

A Smart-Indigo™ machine produces average 1 ton “leuco” indigo per day. A rough calculation says that the pay-back time of a Smart-Indigo™ machine is about 2.54 years which is incredible.

Among denim manufacturers those who think of sustainability in a real sense, they should go with this Smart-Indigo™ technology.

If anyone has any feedback or input regarding the published news, please contact: info@textiletoday.com.bd

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