Development of efficient process to reduce water consumption in textile dye –

house industry for sustainable future for next generation:

To keep the sustainability there is no alternative without reducing the total water consumption
in dye-house for dyeing fabric .As well as we have to keep in mind that our ground water level
goes down everyday. Right now it may not be great concern to us but if we think for our next
generation, it must be a serious issue.

One thing we have to understand that why we are running our industry. Is it only for self-
happiness or for our future generation? Definitely it is for our next generation. So it is not
enough to keep money for their future safety. Also we have to keep a sustainable environment.
From this viewpoint, we are trying to reduce our present water consumption with our existing
dyeing machine (Dilmenler).And finally we have succeeded.

Process currently being used for dyeing colour fabric

A +B+C+D+E+F+G+H+I+J+K+L+M+N+O+P+Q+R;

Where, A=Scouring,30’x110 ; B=Normal Hot,90 ; C= Block wash ; D=Enzyme 60’x55; E=Block

wash; F= Block wash ;G=Levelling+Salt+colour+Soda; H=Rinse,5’;I= Rinse,5’;J= Normal
Hot;K=Block wash or Soaping(depends on Shade);L=Neutralization; M=Block wash; N=Soaping;
O= Block wash P=Block wash; Q=Block wash ;R=Softener &Fixer;

N.B. Every Block wash is carried out for10 minute with cold water

100% cotton Knitted fabric dyeing process:

At first in every recipe we mention how much water we use in different bath. If fabric weight is
900kg then we select 1050 kg m/c capacity. So in scouring &bleaching bath you need 5400
ltr(1:6) where first we took 3900 ltr from reserve tank and then load fabric at 50®c then 500 ltr
with liquid chemical at 50®c,500 ltr with caustic at 60®c with 5’ dossing,500 ltr with peroxide at
80®c with 5’ dosing and then raise temp. at110®c (no grade require below 165 GSM) and run
30’.Next cooling at 80®c(no grade require below 165 GSM) and direct drain. Then take 4050
ltr(1:4.5) from reserve tank which temp. 90®c and run the bath 10’ and then direct drain. Then
take 4050 ltr(1:4.5)cold water from reserve tank and run 10’ and direct drain. Then take 4050
ltr from reserve tank and inject acid (1g/l) to control ph at 4.50 by taking water from m/c vessel.
If ph is ok then inject peroxide killer and enzyme at 55®c by taking water from m/c vessel and
run 60’S and then raise temp. at 80®c and run 10’ and then direct drain. Then two time block
wash with cold water from reserve tank where each with 4050 ltr water for 10’.Then take 3050
ltr from reserve tank and check ph at 6.5 and inject leveling agent from m/c vessel water ,Salt
dose at circulation way from m/c vessel water( for any colour) only 10’ and run 10’and then dye
dosing with 500 ltr at 30’(for any colour) and run 20’ and then soda dose with 500 ltr for
30’with 70% progressive dosing for any color . If colour is turquoise then after colour dosing
and run time, raise temp at 80®c X30’ for migration and then cooling at 60c and soda dossing
done.(All isothermal process , turquoise colour salt, colour, soda dose at 60®c while others at
40®c).Then colour steam start at 60®c (If turquoise 80®c).Then normal hot at 60c for 10’ with
4050 ltr from reserve tank. Then neutralization is done at 60c with 4050 ltr from reserve tank.
Then softener & fixing is injected with 4050 ltr water from reserve rank and before unload
added 1800 ltr (1:2) to free fabric from enzyme dust and unloaded fabric and then drain is
done.

100% cotton white dyeing process:

At first in every recipe we mention how much water we use in different bath. If fabric weight is
650 kg then we select 700 kg m/c capacity. So in scouring & bleaching bath you need 3900
ltr(1:6) where first you take 2700 ltr from reserve tank and then load fabric at 50®c then inject
liquid chemical at 50®c from m/c vessel water,400ltr with caustic at 60®c with 5’ dossing,400ltr
with peroxide at 80®c with 5’ dosing,400 ltr with 4BK at 80®c with 30’ dossing and then raise
temp at 110®c (no gradient is required below 165 GSM) and run 40’ to 60’(depends on
shade).Next cooling at 80®c(no grade require below 165 GSM) and direct drain. Then take
2900ltr (1:4.5) from reserve tank which temp. 90®c and run the bath 10’ and then direct drain.
Then bath wash 2 times with 2900 ltr(1:4.5)cold water in each from reserve tank and run 10’ in
each and direct drain. Then take 2900 ltr from reserve tank and inject acid(1g/l) to control ph at
4.5 by taking water from m/c vessel. If ph is ok then inject Enzyme at 55®c by taking water from
m/c vessel and run 60 minutes and then raise temp. at 80®c and run 10’ and then direct drain.
Then sequestering hot at 70®c to 80®c (depends on shade) and run 10’ with 2900 ltr from
reserve tank. Then two time block wash with cold water from reserve tank where each is 2900
ltr and 10’.Then softener injected with 2900 ltr water from reserve rank and before unload
added 1300 ltr (1:2) to free fabric from Enzyme dust and unloaded fabric and then drain is
done.

100% Polyester dyeing process:

At first in every recipe we mention how much water we use in different bath. If fabric weight is
450 kg then we select 525 kg m/c capacity. Firstly, a detergent and soda hot is done at 90®cX20’
with 2700 ltr (1:6) water from reserve tank. Then a normal hot is carried out with 1700 ltr. After
that we take 1700 ltr from reserve tank and inject acid to control ph at 4 and raise temp at 70®c
and dose dye with 300 ltr water for 15’ Then raise temp 110®c with 1.5®c/min and 110®c to
130®c with 1®c/min and run 40’.Then cooling with same grade at 80®c and check the shade. If
shade is ok then drain and ½ scouring (100®cX30’) is done with 2000 ltr water from reserve
tank. Then one time normal hot and acid wash (for neutralization) is carried out with 2000 ltr
water each time from reserve tank. Then one bath wash is done with 2000 ltr from reserve tank
and unloaded the fabric and drain.

CVC or PC (both part) dyeing process:

At first in every recipe we mention how much water we use in different bath. If fabric weight is
1400 kg then we select 1600 kg m/c capacity. Initially detergent and soda hot is done at
90®cX20’ with 8400 ltr (1:6) water from reserve tank. Then a normal hot wash is carried out
with 6300 ltr. Then take 5300ltr from reserve tank and inject Acid to control ph at 4 and raise
temp at 70®c and dose dye with 1000 ltr water for15’.then raise temp 110®c with 1.5®c/min
and 110®c to 130®c with 1®c/min and run 40’.Then cooling with same grade at 80®c and check
the shade with carbonizing process. If shade is ok then drain and full scouring (100®cX30’) is
done with 6300 ltr water from reserve tank. Then take 6300 ltr(1:4.5) from reserve tank which
temp. 90®c and run the bath 10’ and then direct drain. Then take 6300 ltr (1:4.5)cold water
from reserve tank and run 10’ and direct drain. Then take 6300 ltr from reserve tank and inject
acid (1g/l) to control ph at 4.5 by taking water from m/c vessel. If ph is ok then inject peroxide
killer and enzyme at 55®c by taking water from m/c vessel and run 60’minute and then raise
temp. at 80®c and run 10’ and then direct drain. Then two time block wash with cold water
from reserve tank where each is 6300 ltr and 10’.Then take 4300 ltr from reserve tank and
check ph at 6.5 and inject leveling agent from m/c vessel water ,Salt dose by taking water from
m/c vessel ( for any colour) only 10’ and run 10’and then dyes dosing with 1000 ltr at 30’(for
any colour) and run 20’ and then soda dose with 1000 ltr for 40’ to 50’(for any colour).If
dyestuff is Novacron then soda dose 2 times 30’ is each. If turquoise then after colour run time
raise temp at 80®c X30’ for migration and then cooling and soda dossing done(All isothermal
process ,turquoise colour and Novacron colour ,salt, colour, soda dose at 60®c others at
40®c.Then colour steam start at 60®c (If turquoise 80®c).Then bath drop with 2 times rinse
where each is 5’.Then normal hot 10’ with 6300ltr from reserve tank. Then block wash or
chemical hot wash with 6300 ltr from reserve tank depends on shade. Then neutralization is
done with 6300 ltr from reserve tank. Then block wash or chemical hot wash with 6300 ltr from
reserve tank depends on shade. Then softener & fixing is injected with 6300 ltr water from
reserve rank and before unload added 2800ltr water (1:2) to free fabric from enzyme dust and
unloaded fabric and finally water is drained.

Now we are giving a data on a table where one can easily compare our success

For Colour Fabric:

Fab.Wt Avg M/C

SL.No. Lot Fab. Type Color Water/Kg in Lt Shade %
(Kg) water/Kg Capacity
1 635 1X1 Black 316 72 5
2 685 S/J Navy 280 89 3.6
3 575 S/J Strawberry Ice 267 64 0.25
4 715 S/J Purple Heather 229 70 0.061
5 653 S/J Luminary Green 250 70.4 350 0.088
6 741 1X1 Imperial Blue 250 114 4.238
7 728 1X1 Black 228 96 7.08
8 807 S/J Black 262 95 7.08
9 762 S/J CVC Blue Snow Mell 206 90 2.98
10 825 CCS/J B.P. 46-307 1353 95 1600 0.9+7.2
11 614 S/J 73-203 Blue 360 84 525 3.2
12 824 2X2 Purple Heather 200 74 0.061
13 797 S/J 91-203 G.B. DK 431 92 0.058
525
14 842 S/J 91-203 G.B. DK 433 93 0.058
15 860 S/J 08-105 1390 122.5 T.P 3.672
16 809 S/J 09-105 264 83 4.95
17 814 S/J 08-105 292 98.3 350 3.672
18 938 S/J Black 234 91.5 10.028
19 884 S/J 59-201 858 86.5 7.686
1050
20 837 S/J 09-105 918 90.2 4.95
21 914 S/J Purple Heather 582 94 700 0.061
22 874 S/J Luminary Green 464 99 0.088
23 875 S/J Luminary Green 460 92 0.088
24 900 S/J Luminary Green 450 84.3 525 0.088
88.8304
25 911 PK Yellow 398 98 1.56
26 912 PK Yellow 399 93 1.56
27 905 S/J 09-105 207 104 4.95
350
28 919 S/J 09-090 219 91.7 10.028
29 983 S/J 38-315 429 70.5 525 1.08
30 880 S/J Azure Blue 831 76.8 1050 0.59
31 966 Slub S/J 77-304 456 78.8 0.22
32 976 S/J Luminary Green 453 80.2 525 0.088
33 989 S/J Luminary Green 450 77 0.088
34 993 S/J Black 464 108 7.065
525
35 1016 S/J Black 322 93 5.9
36 853 Slub S/J Black 865 86 5.4
1050
37 977 S/J Granedine 904 85.5 6
38 1009 S/J Luminary Green 454 79.2 0.088
39 1022 S/J Luminary Green 453 79.4 525 0.088
40 1046 S/J Luminary Green 452 79.5 0.088
Schocking
41 1041 100%poly 246 52 1.82
Orange 350
42 1035 1X1 Black 209 115 7.08
43 1056 S/J Port Royal 454 96.8 4.32
525
44 1076 1X1 Phantom 436 88.2 2.23
45 1046 1X1 Phantom 921 99.5 2.23
1050
46 1087 S/J Cloisonne 923 99.2 4.2
47 1024 1X1 Black 1148 121 1400 7.02
 48 1043 PK Black 1209 109 7.08
49 1099 Black(E.B) 286 109 350 6.686
50 1216 08-101(H&M) 297 91.3 350 1.3375
51 1255 Castlerock(Apl) 170 Lycra 105.9 350 1.48
52 1190 84-302(H&M) 180 102.8 350 0.451
53 1272 Doeskin(Apl) 202 96.5 350 0.21
54 1320 Camelia Rose 305 84 350 0.484
55 1327 Black(C&A) 321 85.5 350
56 1182 Black(E.B) 242 121 350 6.82

For White Fabric:

Fabric Water/Kg in Avg

SL.No. Lot Fab. Type Color weight(Kg) Lt water/Kg M/C Capacity
1 708 S/J White 243 24.7
2 838 S/J G.Mell 278 32
3 839 1X1 G.Mell 286 27.6
4 709 S/J G.Mell 248 30.24
5 818 S/J G.Mell 321 30.22
6 714 S/J G.Mell 320 28.4
7 716 S/J G.Mell 326 29.14
8 729A S/J White 308 28.57
9 723 S/J White 227 28.19
10 696 S/J White 250 19.2
11 770 S/J White 227 34.8
12 691 S/J White 185 42.7 350
13 802 S/J Off White 293 29.7
14 855 Fleece G. Mell 313 30
15 856 Fleece G. Mell 312 28.5
16 647 S/J Off White 296 29.7 30.24
17 850 S/J G. Mell 323 28 350
18 928 S/J White 1351 37.6
19 921 S/J Off White 1307 33.4
Only S/C
20 890 S/J Shade 1396 34 1600
21 849 S/J G. Mell 321 31
22 877 S/J G.Mell 321 26.2
23 646 S/J Off White 290 29.3
24 795 S/J Off White 282 32
25 898 S/J Lt. G. Mell 282 30.5
26 899 S/J Lt. G. Mell 280 30.7
27 901 S/J Lt. G. Mell 284 28.9
28 923 S/J G.Lt 302 29.8
29 925 S/J G.Lt 220 33.6
30 932 S/J G.Lt 297 29.6
31 937 S/J Off White 253 29.2 350

Per Day production=16.5ton approximately 70%colour &30%white.

Previous Scenario in our factory:

Average water required for per Kg colored fabric dyeing =135Ltr & for white fabric =60Ltr

Colour fabric weight =11.55ton & water consumption=(11.5*1000*135)ltr=1552500

ltr=1552.5m3

White fabric weight =4.95ton & water consumption= (4.95*1000*60)Ltr=297000Ltr=297m 3

Total water per day= (1552.5+297)m3+10%wastage=2034.45m3

Present scenario of water consumption in our factory:

Average water required for per Kg colored fabric dyeing =90Ltr &for white fabric =34Ltr

Colored Fabric weight =11.55ton & water consumption= (11.5*1000*90)

ltr=1035000Ltr=1035m3

White fabric weight =4.95ton & water consumption= (4.95*1000*34) ltr=168300ltr=207.9m3

Total water consumption per day= (1035+207.9) m3+10% wastage=1367.19m3

So Each day amount of soft-water savings= (2034.45-1367.19) m3=667.26m3

At least we do not need to treat ETP water amounting = 667.26667.26*30%

= 467m3
In our factory, we need 11.5 taka to produce 1m3 soft water and 15.5 taka to treat (ETP)1m3
water

So per day total savings = (667.26*11.5)+(467*15.5)taka=14911.99 taka

So per month total savings = (14911.99*30) taka=447359.7 taka

So per year total savings = (447359.7*12) taka=5368316.4 taka

Comparative analysis of efficient process

SL No Advantage
1 Reducing water consumption at least 40%.
2 Does not effect on fabric quality.
3 Saving salt dosing time.
4 Only scouring is done 1:6(M:L) and all
other 1:4.5(M:L).
Disadvantage
Need to keep operator in close
monitoring.
Need expert operators and sometime
need to change their mentality about
regular process
Need to calibrate dyeing machine.
A flow meter is required for measuring
water level for each m/c.

5 No need rinsing wash except 10 minute.

6 No need extra chemical.

7 Does not need to elaborate current process

and time.
8 Dyeing capacity can be extended with
present WTP & ETP setup.
9 Saving power as it required 40% less water