In textiles production and processing there is intensive use of chemical applications during the fibre manufacturing stage in case of man-made fibres like viscose and in wet processing such as use of bleaching agents and other harmful chemicals, along with dyes. With increasing focus on sustainability, ethical, environmental and socially responsible business structures are the demand of today’s business environment. Huntsman Textile Effects has taken leadership position in this area through a rich product portfolio, initiatives like the Huntsman TE Productivity Improvement Program (PIP) as well as innovative value adding effects and processing solutions. In an exclusive interaction with AO, the Team from Huntsman Textile Effects, a division of Huntsman Corporation charts out the importance and solutions to a sustainable future for the textile industry…
We have brought in new products and technology which help customers in the dyeing process to reduce the consumption of water and energy by over 50% and also help to reduce the effluent discharge – Paul Hulme
Huntsman Textile Effects is committed to developing and driving new standards of environmental sustainability. With a tag line that reads – Enriching lives through innovation – it has introduced a range of new innovative solutions that not only cuts water consumption and reduces energy consumption but also improves productivity. “There is a paradigm shift towards better environment practices, as clearly reflected in the change in environment legislation which has been brought into China more specifically and also in India to conserve water. The key element that we see today is the changing requirement of our customers as water has become almost a scarce commodity. We have brought in new products and technology which help customers in the dyeing process to reduce the consumption of water and energy by over 50% and also help to reduce the effluent discharge,” says Paul Hulme, President of Huntsman TE.
The need for eco-friendly wet processing that is sustainable is on the rise in India and with the help of Huntsman a number of sustainable practices have already been implemented by various textile processing industries such as eco-friendly bleaching; peroxide bleaching; eco-friendly dyeing and printing; low impact dyes; natural dyes; azo-free dyes; phthalates free printing to name a few.
Energy & Water Saving Products of Huntsman
Huntsman Textile Effects recently held a seminar in Singapore for key industry players to make sustainability a key point in their agenda and take a collective commitment to conserve water and energy resources. Carrying the thought forward, at the forthcoming ITMA, Huntsman is showcasing all its new products which have been in the market over in the last six months and some fresh products and technologies with sustainable properties. Sharing the details, Rohit Aggarwal, Global Vice-President, Apparel Home & Textile says, “The focus product would be ‘Avitera’ a revolution in reactive dyeing, a change technology for the industry.” Huntsman claims that Avitera can save 50% of water and about 70% energy consumption, whereas in processing one kg of cotton, Avitera helps to save 30 litres of water and 1.5 kg of CO2 emission. “For conventional dyes 6-8 baths at high temperature are necessary but with Avitera dyes, 3 to 4 baths at 60 degree Celsius are sufficient because of the higher diffusion speed and very high fixation rate close to the exhaustion rate,” explains Rohit.
The product ensures increase in productivity without additional capital investment, thus minimizing processing costs and increase in profitability. “Exceed environmental legislation targets and differentiate yourself from competitors,” says Rohit.
Digital Printing — A Sustainable Solution
According to a survey conducted by Hunstman, total global production volume of printed textiles currently is 25-30 billion metres per annum, of which around 97% is screen printed and remaining 3% is digitally printed. “Analysts predict that within 5 years 15% of globally printed textiles will be made digitally,” avers Kent Kvaal, Vice-President, Specialty Textiles, Huntsman.
As per Kent two things which are necessary for ink jet to become mainstream is increasing speed and efficiency of the processes so as to become more competitive than rotary printing. “Huntsman is very committed to development in this direction and we are working with key equipment and printing head manufacturers in the world to support and aid greater speed and efficiency in digital printing,” informs Kent. Huntsman would also be showcasing innovative Ink-jet printing at ITMA 2011.
The advantages of digital printing are many, as it overcomes several technical limitations of traditional printing. Also there is no limitation in number of colours with greater design freedom. “Excellent shade gradations and 3-D effects can be given in digital printing. There is no limitation on repeat length. The best part is that it provides low cost sampling, while screen print sampling is expensive and time-consuming. Also, in digital printing process, no colour kitchen is required, as colours are mixed on the fabric directly,” says Kent. Further, in digital printing minimal time is consumed between sample approval and production.
The versatility of digital printing has the ability to cope with fast changing design collections and allows for lower stocks for whole supply chain. The best advantage of this technology is that there is less colourant usage and no wastage. “Low amount of unfixed dyes, less water and energy for washing, fewer colours in effluent,” highlights Kent according to whom the only real problem is the limitation of mass production and the cost involved per piece, which is pretty high in digital printing.
The focus product would be ‘Avitera’ a revolution in reactive dyeing, a change technology for the industry Avitera can save 50% of water and about 70% energy consumption – Rohit Aggarwal
Though the digital printing market is growing fast, it is still a small segment of the textile printing industry. The fastest growing segment in application of digital printing according to Kent is wide format apparel on new industrial inkjet machines. “Today, digital is replacing flat-screen printing machines due to similar colouration costs and production speeds, and one such example is T-shirts printing which is growing via online businesses. Similarly, home textiles, automotive fabrics, outdoor applications are niche areas that are now rapidly developing in digital printing,” remarks Kent.
Within 5 years, 15% of globally printed textiles will be made digitally two things which are necessary for ink jet. Increasing speed and efficiency of the processes is required to become more competitive than rotary printing – Kent Kvaal
Commitment to Sustainability
Huntsman believes in working very closely with its clients to update them with new efficient and sustainable technologies. “We have people on the ground to work with our customers to introduce new technologies and help them to improve their processing facilities. We have productivity improvement programmes which support some key customers to improve their productivity; reduce water and energy consumption, improve their turnaround time and shorten processes. We also run training programmes with some of our key customers; also help local brands and retailers in India, understand the production processes within the industry so that they can take decision as per their requirements. In fact, we are fully committed to stand with our customers in markets across the world in their quest for sustainable solutions in chemicals,” concludes Steve Gray, Vice-President of Huntsman TE Research and Technology.
