Abstract
The sustainability of garment washing processes, especially denim washing, is indeed a critical concern in today's fashion industry. The aesthetic appeal and design of a garment play a significant role in influencing consumer choices. Presently, denim lovers have a multitude of options, including advanced and organic denim, eco-denim initiatives, zero water technologies, oxygen and ozone washes, and less polluting methods of fabric dyeing and washing. However, despite their promotional claims, many of these options may not be as eco-friendly as they are marketed to be. This paper intends to draw a comparison between conventional washing methods (dark, medium, and light wash) and their sustainable counterparts (dark wash, medium wash, and light wash). With an emphasis on their benefits, the study offers a thorough comparison of conventional and sustainable washing techniques. Both methods can achieve the same garment appearance, but sustainable washing proves to be more efficient, saving at least 20 minutes per wash. Light washing saves an extra 2.1 L per garment, and medium and dark washes save 8.85 L and 6 L more than conventional methods. Although, energy consumption is higher in sustainable washing (1.92 Kwh/garment) compared to conventional washing (1.15 Kwh/garment), but it reduces chemical usage significantly. It saves 16, 21, and 21 points on a chemical impact scale for light, medium and dark washes, respectively. The study also considers the impact on workers, which is lower in sustainable washing (96) compared to conventional methods (163.5), resulting in a saving of 79 points. Lastly, the Environmental Impact Measurement (EIM) score is lower in sustainable washing (29 for light, 32 for medium and 30 for dark wash) compared to conventional methods (45 for light, 49 for medium and 48 for dark wash). This suggests that sustainable washing is not only more efficient, but also more environmentally friendly. It's a great reminder of the importance of sustainable practices in our daily lives. The EIM software was used to calculate an overall score. According to the EIM software rating, any score above 66 indicates a high environmental impact, which is detrimental to the environment (0-33 low impact, 34-66 medium impact).
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1 Introduction
The global denim company is growing rapidly as a result of denim culture's increasing appeal. Denim, one of the most classic clothing materials utilized in the fashion industry today, is still recognized and worn by a large number of people globally (Arikan et al., 2015). The modern denim masters were the forerunners of the industrialization of jeans at that time.
(Garcia, 2015a). Particularly for wet treatments, significant quantities of chemicals, pigments, and water are required. One pair of jeans requires 100 gallons of water to wash during production, despite the fact that denim clothing is becoming more and more popular around the world. According to the findings, the denim industry uses more than 18 billion gallons of water a year.
Even if fashions change, denim is still fashionable, yet cleaning denim is not environmentally friendly. As a result, it frequently occurs in poor countries where environmental regulations are not well established (Shamim et al., 2020). Beyond age, gender, climatic conditions, and economic status, its acceptability is rising (Gusakov et al., 2000). Denim has already become a "classic" in the current fashion cycle thanks to several inventions and development efforts over the past few decades (Hosen et al., 2021). With technological improvements, consumer expectations for denim fabric have fluctuated over time. Modern consumers nowadays aren't just focused on new trends and creative designs (Muscio, 2006) but also desire to participate in consumer sustainability, user-friendly performance, and comfortable garments (Buysse & Verbeke, 2003). It is important to be compatible with strategically important market circumstances and expanding client expectations (Islam et al., 2021). Apparel designers are actively working to create several unique denim garment variants by physically and chemically modifying the fabric's morphology (Alkaya & Demirer, 2014). For instance, demand for environmentally friendly, nontoxic products has increased (Kumar et al., 2021) to completely biodegradable goods with garment-washing technology (Irwin et al., 1999). Sustainable and ecologically friendly washing technology has previously sought to alter garments' view, appearance, and comfortability by applying several physical, chemical, and mechanical activities (Nayak & Padhye, 2015). Meanwhile, the profitable embellishment in fabrics and apparels that comes with garment washing (Shamsuzzaman et al., 2021). Additionally, it lessens soluble substances like colors, unfixed compounds, and others from the cloth surface (Mondal et al., 2016). It’s clear that not having access to clothes washing facilities can lead to unhygienic conditions. (Abdelfattah Halleb et al., 2015). The physical and structural qualities of textile articles are enhanced by the dry washing procedure (Juciene et al., 2006). It is limited to enabling the mechanical cleaning process, also known as whiskering, scraping, grinding, and tagging (Karmakar, 1999). The wet procedure, on the other hand, comprises stone washing, acid washing, ultra-whitewashing, enzyme washing, and hot washing (Dudeja, 2018). These allow for surface alterations to be made to fabrics and clothing simply by chemical processing (Paul, 2015). According to the quality requirements set out by the buyer, various physical and chemical procedures are combined and applied to the surfaces of the clothes (Jönsson et al., 2018; Schindler & Hauser, 2004). In an era where sustainability is paramount, the integration of advanced technology and innovative materials has emerged as a focal point of scientific exploration (Hosseinzadeh et al., 2023). These cutting-edge technologies hold immense promise for addressing critical global challenges, including environmental remediation, renewable energy production, and sustainable materials development (Ghodrati et al., 2020). In this context, green nanotechnology and advanced materials play pivotal roles in shaping a more sustainable future. Researchers worldwide have embraced the 12 principles of green chemistry, which advocate for reduced environmental impact, energy efficiency, and safer chemical products (Murthy et al., 2023; Zinatloo-Ajabshir et al., 2019). By harnessing nanoscale phenomena, green nanotechnology enables the creation of novel materials with enhanced properties. These materials find applications in diverse fields, from medicine to energy storage. As researchers delve deeper into advanced materials and composites, they explore innovative manufacturing techniques, digital twin technologies, and machine learning algorithms to optimize material performance and minimize environmental footprints (Sobhani, 2023). By integrating these advancements, pave the way for sustainable structures that balance human needs, environmental stewardship, and economic viability (Zinatloo-Ajabshir & Salavati-Niasari, 2019). The conventional denim washing process is the regular basis washing technique to apply for the denim dry process & wet process. In the conventional washing process, need more water, chemicals & power. Sometimes, this is not favorable for the environment & future world. On the other hand, for the sustainable denim washing process just need less water, chemical (sustainable) & power rather than conventional wash. Simply said, garment cleaning refers to the technology used on clothing to create new designs and trends, enhance decorative appeal, and increase comfort. In common parlance, washing simply refers to cleansing something that is filthy. It includes mechanical and chemical cleaning processes as well as surface modification of textiles and garments. Both printed cloth and garments with solid dyes can be treated with it. Typically, denim is only a 2/1 or 3/1 twill fabric made of raw white weft yarn and dyed warp yarn (either Sulphur or Vat). Size compounds are put to warp yarn during the weaving process to fortify the thread and make it more resistant to mechanical wear in the loom. To provide user-friendly experiences, it is essential to reduce the stiffness of clothing. Over the years, garment-washing technologists have used various efficient dry and wet processes to make fabric surfaces soft and smooth. Additionally, the mechanical operations are sometimes referred to as the "garments dry process," which includes the 3D crinkle effect, hand sanding, grinding, and whiskering. It is often applied to unwashed fabrics and garments right before the first wash. Additionally, it permits various mechanical abrasions and gives fabric surfaces a worn-out look. In addition to the dry process, raw garments are subjected to wet processes, including enzyme washing, super whitewashing, acid washing, and stone washing, in order to remove impurities (size materials, dirt, and dust) from the textiles' subsequent processes. Thus, in contrast to an unwashed sample, it creates a fresh, soft, smooth, and worn-out look. Fast fashion trends are encouraging people to buy high-quality apparel items made of sustainable materials at affordable price (Khandual & Pradhan, 2019). These technical results include process integration, picking the best washing technique, using process variables correctly, and using the essential chemicals for washing clothes. A variety of techniques and wash recipes were used in this study to differentiate between conventional and sustainable washes. The comparison was made on several factors, including wash cost, EIM score, time, water, energy, chemical impact, and worker impact. It found that both conventional and sustainable washes resulted in the same appearance. However, the sustainable wash had the added benefits of saving at least 20 min of washing time and reducing chemical usage. This not only helps in mitigating environmental safety issues but also reduces the impact on workers. The EIM scores for light, mid, and dark washes in the sustainable method were 29, 32, and 30, respectively, all of which fall under the sustainable category, indicating a low environmental impact. On the other hand, the EIM scores for the conventional method were significantly higher, with 45 for a light wash, 49 for a mid-wash, and 48 for a dark wash. The study conclusively shows that sustainable washing methods have clear environmental advantages over conventional methods.
2 Materials and methods
2.1 Materials
Twill fabric (fabrication: 100% organic cotton twill-3/1, Wt-9.80 Oz/yd2) used for the project to compare the EIM scores between sustainable wash and conventional wash (Fig. 1).
Before washing fabric swatch
2.2 Garments sample details of Fig. 2
After washing garments, Outlook sample
Garments type: Denim Jacket, Garments size: 3-year-old children, Fabrication: 100% Organic Cotton, Construction: Twill-3/1,70 × 44 × 10 × 9, Wt-9.80 Oz/Yd2, C/W-58''. The denim jacket is made using a conventional and sustainable method, utilizing both dry and wet processes.
2.3 Garments drying method
Washing garments manually or mechanically enhances their appearance and increases their value (Parvez et al., 2019). The method of drying clothing involves manual sanding, tagging, destruction, the 3D crinkle effect, grinding, and whiskering in order to preserve its structural integrity. There were two types of grinding tools used: (a) roller grinding and (b) grinding pens.
2.4 Flow chart of the dry process for garments
Raw garments > Hand scraping > Whiskering > Tagging > Start with a first wash (such as a normal, enzyme, or acid wash) > followed by Hydro-extraction > Drying > P.P. spray > Grinding > Washing > Neutralization > Softening and Finishing.
2.4.1 Whiskering
One of the most crucial activities in the dry-processing of clothing is whiskering, which is the initial phase (Zayedul Hasan et al., 2021). The design creates a variety of whiskering patterns to give clothing a faded or whiskered appearance. This is usually done by scrubbing the pattern using emery paper or an abrasive. The most effective methods are hand scraping, a method that provides extreme control and precision, applying a laser device, which is a contemporary, accurate, and efficient technique that is becoming increasingly well-liked in the industry, and using a whiskering pattern, which replicates natural denim wear and tear (Fig. 3).
Sample manual whiskering
2.4.2 Hand sand
Hand sanding is a process that follows whiskering in the treatment of denim clothes. It’s used to give the clothes a worn-out appearance. The process involves the use of a horizontal air dummy, gum tapes, and abrasive paper. Hand sanding is often preferred as a healthier alternative to sandblasting, which has been associated with health risks (Fig. 4).
Stretch denim's back portion hand-sanded
2.4.3 Tagging
When clothing is still unwashed, tagging is used (Zayedul Hasan et al., 2021). After the washing process, the effects of hand sanding and whiskering become visible, giving the denim clothes their distinctive worn-out look. The operators spend a significant amount of time folding the garments, particularly those from the outer areas. However, it’s worth noting that on rare occasions, this technique might cause a hole to form in the clothes, which is an unintended consequence of the process. When using these techniques, this is something to be mindful of (Fig. 5).
Tagging on waistband area
2.4.4 Destroy
The most popular method of distressing is destruction, which is done with a pen grinder and stones of different sizes (Zayedul Hasan et al., 2021). Clothes look to have holes and tattered white threads, which adds to their uniqueness and flair (Fig. 6).
Destroy effect on denim
2.4.5 3D Crinkle
It is one of the critical finishing treatments used for denim apparel after the wet process. The term "3D crinkle" refers to the use of polymers to give denim garments a 3D appearance. These substances prevent the fabric from converting to its regular position when it deforms, folds, or loses its natural orientation, which causes wrinkles or creases. Using resins like low-formaldehyde or DMDHEU-type resins that create crosslinks between cellulose linkages, this procedure is carried out either manually or semi-automatically. A range of supportive auxiliaries are employed to increase the penetration of softening resins and softeners (Fig. 7).
Picture of 3D crinkle process
2.5 Eco-friendly garments wet processing in the apparel industries for sustainable wash
To modify or change the view, appearance, comfort, and design of clothes, a procedure called the "garment wet process" is employed. Garment washing is used on solid-colored garments and solid-colored printed fabric (Fig. 8).
Operation of the garment's wet process is ongoing
2.5.1 The purpose of clothes wet processing can be used to
The clothing preparation process optimizes garment quality and appeal. It ensures immediate wearability, enhances visual and tactile appeal through brightness and smoothness, and provides a comfortable, personalized fit. It also applies treatments for a unique color fading aesthetic and improved softness. Finally, it ensures wearer safety and health by removing any harmful materials.
2.5.2 Chemicals used in the wet process for sustainable garments
The enzyme, detergent, acetic acid [CH3-COOH], anti-staining agent, powder for bleaching [Ca (OCl)Cl], caustic soda (NaOH), soda ash (Na2CO3), sodium bicarbonate (NaHCO3), and sodium hyposulfite (Na2S2O2) are examples of substances. Flax softener is a cationic and nonionic silicon microemulsion, sodium, buffer, stabilizer, and hydrogen peroxide (H2O2) fixing and optical brightening agent.
2.6 Wet processes in the textile and apparel sectors (chemical washing process)
There are so many wet processes in the Textile & Apparel industry, such as Super White Wash, Acid Wash, Enzyme Wash, Stone Wash, and Bleach Wash. Most of the time, those wet processes are applied to denim garments.
2.6.1 Garments wet process types
Acid wash, Enzyme-stone wash, Bleach-stone wash, Pigment wash, Enzyme wash, Stone wash, and Normal wash/Detergent wash.
2.6.2 Garment wet process tools
Sample washing machines (horizontal or vertical type), washers (side- or front-loading), hydro extractors, steam or gas dryers, machines for mixing chemicals, industrial ovens (gas or electric), boilers, submersible pumps, grinders, tagging machines, steam chambers for wrinkles, etc. Sample horizontal and vertical washing machines, front-loading and side-loading dryers, steam- and gas-powered dryers, and a machine for mixing chemicals are all included.
2.6.3 Super white wash
The super white wash process, which uses chemicals like OBA (Optical Brightening Agent) to wash grey cotton fabric, enhances whiteness, hand feel, and reduces extra material in stretch denim apparel, resulting in a vibrant, clean, and comfortable wear experience (Fig. 9).
A sample of stretchy, super-white-washed denim
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(i)
Super white wash SOP
See Table 1.
2.6.4 Acid wash
Usually, it is used for clothing made of heavy materials like denim (Engineering and 2017, n.d.), course twill and canvas, etc. Pumice stones and acid wash can occasionally combine. By using pumice stones, the surface of the garment develops an erratic fading look (Card et al., 2006). The portions of the fabric with several layers, such as the collar, pocket, placket, side seam, and so forth, will be brushed more than the areas with only one layer (Khalil et al., 2016). Increasing softness, enhancing rubbing speed, and producing an uneven fading appearance are the three tactics that this article aims to illustrate (Fig. 10).
Sample of acid-washed denim
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(i)
Acid wash SOP
See Table 2.
2.6.5 Enzyme wash
Biochemical compounds known as enzymes depend as catalysts for specific chemical processes (Reidies et al., 1992). Regarding chemistry, the enzymes' excellent specificity to target a certain substrate only makes them highly intriguing (Hossain et al., 2017). The enzyme activity hydrolyzes the cellulose during the enzyme wash (Mondal et al., 2013a) (Fig. 11).
Sample of enzyme wash denim
Enzymes, either acid or non-acid, are used in denim washing to enhance clothing's softness, color and rubbing resistance, "Bio-Polishing" effect, and anti-pilling properties.
-
(i)
Enzyme wash SOP
See Table 3.
2.6.6 Stone wash
Enzyme activity during enzyme Stone washing is used to create a fading and discoloration effect on the surface of clothing, and it also hydrolyzes the cellulose (Mondal et al., 2013b). Stone washing uses perforated stones that are produced by volcanic eruptions. These stones are also known as pumice stones. To give them an old and worn-out look, heavy textiles like denim and jeans are also washed. For more fading or discoloration, use fewer brush strokes; for uneven fading of garments, use pumice stones (Fig. 12).
Stone-washed denim sample
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(i)
Stone wash SOP
See Table 4.
2.6.7 Bleach wash
Clothing and accessories that have been indigo-dyed and are normally colored using reactive or direct dye are referred to as being bleached (Mir et al., 2014). Furthermore, it is a unique technique that may be applied in place of or in addition to stone cleaning (Sarkar & Khalil, 2014). This process must be followed to avoid problems with yellowing. The process of enzyme or stone washing involves the use of bleaching to create a super-light color or a more fading appearance (Fig. 13).
Bleach wash denim garments
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(i)
Bleach wash SOP
See Table 5.
2.7 Wash details (conventional & sustainable)
Depending on the intended result, different washing techniques are used for jeans. A little base wash, a front/back blast, and mild edge grinding are all part of the dry process for a light wash. Similar steps are taken for the medium wash, however a medium base wash is used instead. Finally, the dark wash employs the same dry procedure as the previous two but with a dark base wash (Tables 6, 7, 8, 9, 10, 11, 12 and 13).
2.8 Wash recipe
2.8.1 Light wash (conventional)
Wash Name: Light wash (Conventional) | Dry process Number: DP-905 | Garment type: Denim jacket | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Washing Machine Info: | Wash Machine type & Capacity | Front Loading | |||||||||||
Washing Machine RPM | 22 | ||||||||||||
Dryer's Info: | Dryer type (Steam / Gas) & Capacity | Steam Dryer | |||||||||||
Drying Temperature (degree Celsius) | 65 | ||||||||||||
Drying Time min | 45 | ||||||||||||
Dry Process Info: H/S, Knicking, Grinding, PP spray | |||||||||||||
Wet Process Info: Desize, Enzyme, Bleach, Neutral, Softening | |||||||||||||
Recipe format | |||||||||||||
SL | Process | Chemical Name | Commercial Name of chemical | Chemical Company Name | Dosages in gm | Water in Ltr | Material: Liquor Ratio | pH | Tamp°C | Time in Minutes | Remarks | ||
1 | Desize | EPQ-700 | Detergent + Lycra Protector | ABC | 100 | 100 | 1:10 | 50 | 10 | ||||
Pumic Stone | Pumic Stone | 3KG | |||||||||||
2 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
3 | Enzyme | Valuemax | Neutral Enzyme | NC | 100 | 80 | 1:08 | R/T | 20 | check | |||
EPQ-700 | Detergent + Lycra Protector | ABC | 80 | 100 | 50 | ||||||||
4 | Rinse. × 2 | ||||||||||||
5 | Bleaching | KCI Bleach | Bleach | BB | 1500 | 100 | 1:12 | 12 | 50 | 13to15 | Timely Check | ||
Soda | Soda | 50 | |||||||||||
6 | Rinse. × 2 | 100 | R/T | 15 | |||||||||
7 | Neutral | Sodium Metabisulfite | Sodium Metabisulfite | BB | 150 | 100 | 1:10 | 5.5 | R/T | 5 | pH Check | ||
8 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
Hydro & steam dryer-Send to PP spray, Knicking, Grinding | |||||||||||||
9 | PP Neutral | Sodium Metabisulfite | Sodium Metabisulfite | BB | 150 | 100 | 1:10 | 5.5 | R/T | 5 | pH Check | ||
10 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
11 | Softener | Belbacine OZK | Antiozonate softener | BB | 200 | 100 | 5.5 | R/T | 10 | pH check | |||
Citric Acid | Citric Acid | BB | 100 | ||||||||||
13 | Hydro-extraction | 10 | |||||||||||
14 | Tumble Dryer | 70 | 40 | ||||||||||
Total Time in Minutes | 124 | ||||||||||||
2.8.2 Medium wash (conventional)
Wash Name: Med wash (Conventional) | Dry process Number: DP-871 | Garment type: Denim jacket | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Washing Machine Info: | Wash Machine type & Capacity | Front Loading | |||||||||||
Washing Machine RPM | 22 | ||||||||||||
Dryer's Info: | Dryer type (Steam / Gas) & Capacity | Steam Dryer | |||||||||||
Drying Temperature (degree Celsius) | 65 | ||||||||||||
Drying Time min | 45 | ||||||||||||
Dry Process Info: H/S, Knicking, Grinding, PP spray | |||||||||||||
Wet Process Info: Desize, Enzyme, Bleach, Neutral, Tint, Softening | |||||||||||||
Recipe format | |||||||||||||
SL | Process | Chemical Name | Commercial Name of chemical | Chemical Company Name | Dosages in gm | Water in Ltr | Material: Liquor Ratio | pH | Tamp°C | Time in Minutes | Remarks | ||
1 | Desize | EPQ-700 | Detergent + Lycra Protector | ABC | 100 | 100 | 1:10 | 50 | 10 | ||||
Pumic Stone | Pumic Stone | 3KG | |||||||||||
2 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
3 | Enzyme | Valuemax | Neutral Enzyme | NC | 100 | 80 | 1:08 | R/T | 20 | check | |||
EPQ-700 | Detergent + Lycra Protector | ABC | 80 | 100 | 50 | ||||||||
4 | Rinse. × 2 | ||||||||||||
5 | Bleaching | KCI Bleach | Bleach | BB | 1500 | 100 | 1:12 | 12 | 50 | 10to12 | Timely Check | ||
Soda | Soda | 50 | |||||||||||
6 | Rinse. × 2 | 100 | R/T | 15 | |||||||||
7 | Neutral | Sodium Metabisulfite | Sodium Metabisulfite | BB | 150 | 100 | 1:10 | 5.5 | R/T | 5 | pH Check | ||
8 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
Hydro & steam dryer-Send to PP spray, Knicking, Grinding | |||||||||||||
9 | PP Neutral | Sodium Metabisulfite | Sodium Metabisulfite | BB | 150 | 100 | 1:10 | 5.5 | R/T | 5 | pH Check | ||
10 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
11 | Tint | Direct Dyes | Brown GTL | 0.5gm | 100 | 45 | 5 | ||||||
G. Salt | G. Salt | 100 | |||||||||||
12 | Softener | Belbacine OZK | Antiozonate softener | BB | 200 | 100 | 5.5 | R/T | 10 | pH check | |||
Citric Acid | Citric Acid | BB | 100 | ||||||||||
13 | Hydro-extraction | 10 | |||||||||||
14 | Tumble Dryer | 70 | 40 | ||||||||||
Total Time in Minutes | 129 | ||||||||||||
2.8.3 Dark wash (conventional)
Wash Name: Dark wash (Conventional) | Dry process Number: DP-923 | Garment type: Denim jacket | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Washing Machine Info: | Wash Machine type & Capacity | Front Loading | |||||||||||
Washing Machine RPM | 22 | ||||||||||||
Dryer's Info: | Dryer type (Steam / Gas) & Capacity | Steam Dryer | |||||||||||
Drying Temperature (degree Celsius) | 65 | ||||||||||||
Drying Time min | 45 | ||||||||||||
Dry Process Info: H/S, Knicking, Grinding, PP spray | |||||||||||||
Wet Process Info: Desize, Enzyme, Bleach, Neutral, Tint, Softening | |||||||||||||
Recipe format | |||||||||||||
SL | Process | Chemical Name | Commercial Name of chemical | Chemical Company Name | Dosages in gm | Water in Ltr | Material: Liquor Ratio | pH | Tamp°C | Time in Minutes | Remarks | ||
1 | Desize | EPQ-700 | Detergent + Lycra Protector | ABC | 100 | 100 | 1:10 | 50 | 10 | ||||
2 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
3 | Enzyme | Valuemax | Neutral Enzyme | NC | 100 | 80 | 1:08 | R/T | 20 | check | |||
EPQ-700 | Detergent + Lycra Protector | ABC | 80 | 100 | 50 | ||||||||
4 | Rinse. × 2 | ||||||||||||
5 | Bleaching | KCI Bleach | Bleach | BB | 500 | 100 | 1:12 | 12 | 50 | 4to5 | Timely Check | ||
Soda | Soda | 50 | |||||||||||
6 | Rinse. × 2 | 100 | R/T | 15 | |||||||||
7 | Neutral | Sodium Metabisulfite | Sodium Metabisulfite | BB | 150 | 100 | 1:10 | 5.5 | R/T | 5 | pH Check | ||
8 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
Hydro & steam dryer-Send to PP spray, Knicking, Grinding | |||||||||||||
9 | PP Neutral | Sodium Metabisulfite | Sodium Metabisulfite | BB | 150 | 100 | 1:10 | 5.5 | R/T | 5 | pH Check | ||
10 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
11 | Tint | Direct Dyes | Grey | 0.6gm | 100 | 45 | 5 | ||||||
G. Salt | G. Salt | 100 | |||||||||||
12 | Softener | Belbacine OZK | Antiozonate softener | BB | 200 | 100 | 5.5 | R/T | 10 | pH check | |||
Citric Acid | Citric Acid | BB | 100 | ||||||||||
13 | Hydro-extraction | 10 | |||||||||||
14 | Tumble Dryer | 70 | 40 | ||||||||||
Total Time in Minutes | 129 | ||||||||||||
2.8.4 Light wash (sustainable)
Wash Name: Light wash (Sustainable) | Dry process Number: DP-905 | Garment type: Denim jacket | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Washing Machine Info: | Wash Machine type & Capacity | Front Loading | |||||||||||
Washing Machine RPM | 22 | ||||||||||||
Dryer's Info: | Dryer type (Steam / Gas) & Capacity | Steam Dryer | |||||||||||
Drying Temperature (degree Celsius) | 65 | ||||||||||||
Drying Time min | 45 | ||||||||||||
Dry Process Info: Knicking, Grinding, Laser Brush | |||||||||||||
Wet Process Info: Desize, Bleach, Neutral, Softening | |||||||||||||
Recipe format | |||||||||||||
SL | Process | Chemical Name | Commercial Name of chemical | Chemical Company Name | Dosages in gm | Water in Ltr | Material: Liquor Ratio | pH | Tamp°C | Time in Minutes | Remarks | ||
1 | Desize | EPQ-700 | Detergent + Lycra Protector | ABC | 100 | 100 | 1:10 | 50 | 10 | ||||
Pumic Stone | Pumic Stone | 3KG | |||||||||||
2 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
3 | Bleaching | KCI Bleach | Bleach | BB | 1500 | 100 | 1:12 | 12 | 50 | 13 to 15 | Timely Check | ||
Soda | Soda | 50 | |||||||||||
4 | Rinse. × 2 | 100 | R/T | 15 | |||||||||
5 | Neutral | Sodium Metabisulfite | Sodium Metabisulfite | BB | 150 | 100 | 1:10 | 5.5 | R/T | 5 | pH Check | ||
6 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
Hydro & steam dryer-Send to Laser Brush, Knicking, Grinding | |||||||||||||
7 | PP Neutral | Sodium Metabisulfite | Sodium Metabisulfite | BB | 150 | 100 | 1:10 | 5.5 | R/T | 5 | pH Check | ||
8 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
9 | Softener | Belbacine OZK | Antiozonate softener | BB | 200 | 100 | 5.5 | R/T | 10 | pH check | |||
Citric Acid | Citric Acid | BB | 100 | ||||||||||
10 | Hydro-extraction | 10 | |||||||||||
11 | Tumble Dryer | 70 | 40 | ||||||||||
Total Time in Minutes | 104 | ||||||||||||
2.8.5 Medium wash (sustainable)
Wash Name: Med wash (Sustainable) | Dry process Number: DP-871 | Garment type: Denim jacket | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Washing Machine Info: | Wash Machine type & Capacity | Front Loading | |||||||||||
Washing Machine RPM | 22 | ||||||||||||
Dryer's Info: | Dryer type (Steam / Gas) & Capacity | Steam Dryer | |||||||||||
Drying Temperature (degree Celsius) | 65 | ||||||||||||
Drying Time min | 45 | ||||||||||||
Dry Process Info: Knicking, Grinding, Laser Brush | |||||||||||||
Wet Process Info: Desize, Bleach, Neutral, Softening | |||||||||||||
Recipe format | |||||||||||||
SL | Process | Chemical Name | Commercial Name of chemical | Chemical Company Name | Dosages in gm | Water in Ltr | Material: Liquor Ratio | pH | Tamp°C | Time in Minutes | Remarks | ||
1 | Desize | EPQ-700 | Detergent + Lycra Protector | ABC | 100 | 100 | 1:10 | 50 | 10 | ||||
Pumic Stone | Pumic Stone | 3KG | |||||||||||
2 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
3 | Bleaching | KCI Bleach | Bleach | BB | 1500 | 100 | 1:12 | 12 | 50 | 10 to 12 | Timely Check | ||
Soda | Soda | 50 | |||||||||||
4 | Rinse. × 2 | 100 | R/T | 15 | |||||||||
5 | Neutral | Sodium Metabisulfite | Sodium Metabisulfite | BB | 150 | 100 | 1:10 | 5.5 | R/T | 5 | pH Check | ||
6 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
Hydro & steam dryer-Send to Laser Brush, Knicking, Grinding | |||||||||||||
7 | PP Neutral | Sodium Metabisulfite | Sodium Metabisulfite | BB | 150 | 100 | 1:10 | 5.5 | R/T | 5 | pH Check | ||
8 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
9 | Tint | Direct Dyes | Brown GTL | 0.5gm | 100 | 45 | 5 | ||||||
G. Salt | G. Salt | 100 | |||||||||||
10 | Softener | Belbacine OZK | Antiozonate softener | BB | 200 | 100 | 5.5 | R/T | 10 | pH check | |||
Citric Acid | Citric Acid | BB | 100 | ||||||||||
11 | Hydro-extraction | 10 | |||||||||||
12 | Tumble Dryer | 70 | 40 | ||||||||||
Total Time in Minutes | 109 | ||||||||||||
2.8.6 Dark wash (sustainable)
Wash Name: Dark wash (Sustainable) | Dry process Number: DP-923 | Garment type: Denim jacket | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Washing Machine Info: | Wash Machine type & Capacity | Front Loading | |||||||||||
Washing Machine RPM | 22 | ||||||||||||
Dryer's Info: | Dryer type (Steam / Gas) & Capacity | Steam Dryer | |||||||||||
Drying Temperature (degree Celsius) | 65 | ||||||||||||
Drying Time min | 45 | ||||||||||||
Dry Process Info: Knicking, Grinding, Laser Brush | |||||||||||||
Wet Process Info: Desize, Bleach, Neutral, Tint, Softening | |||||||||||||
Recipe format | |||||||||||||
SL | Process | Chemical Name | Commercial Name of chemical | Chemical Company Name | Dosages in gm | Water in Ltr | Material: Liquor Ratio | pH | Tamp°C | Time in Minutes | Remarks | ||
1 | Desize | EPQ-700 | Detergent + Lycra Protector | ABC | 100 | 100 | 1:10 | 50 | 10 | ||||
2 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
3 | Bleaching | KCI Bleach | Bleach | BB | 500 | 100 | 1:12 | 12 | 50 | 4to5 | Timely Check | ||
Soda | Soda | 50 | |||||||||||
4 | Rinse. × 2 | 100 | R/T | 15 | |||||||||
5 | Neutral | Sodium Metabisulfite | Sodium Metabisulfite | BB | 150 | 100 | 1:10 | 5.5 | R/T | 5 | pH Check | ||
6 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
Hydro & steam dryer-Send to Laser Brush, Knicking, Grinding | |||||||||||||
7 | PP Neutral | Sodium Metabisulfite | Sodium Metabisulfite | BB | 150 | 100 | 1:10 | 5.5 | R/T | 5 | pH Check | ||
8 | Rinse. × 2 | 100 | R/T | 3 | |||||||||
9 | Tint | Direct Dyes | Grey | 0.6gm | 100 | 45 | 5 | ||||||
G. Salt | G. Salt | 100 | |||||||||||
10 | Softener | Belbacine OZK | Antiozonate softener | BB | 200 | 100 | 5.5 | R/T | 10 | pH check | |||
Citric Acid | Citric Acid | BB | 100 | ||||||||||
11 | Hydro-extraction | 10 | |||||||||||
12 | Tumble Dryer | 70 | 40 | ||||||||||
Total Time in Minutes | 109 | ||||||||||||
3 Results and discussion
The EIM scores for light, mid, and dark washes in the sustainable method were 29, 32, and 30, respectively, all of which fall under the sustainable category, indicating a low environmental impact. On the other hand, the EIM scores for the conventional method were significantly higher, with 45 for a light wash, 49 for a mid-wash, and 48 for a dark wash. Here we can see the all results from the below tables.
3.1 Conventional & sustainable wash effect (dark wash, med wash & light wash) garments picture
Washing process | Conventional wash | Sustainable wash |
|---|---|---|
Dark wash |
|
|
Medium wash |
|
|
Light wash |
|
|
3.2 Impact of time
We can see that those sustainable washes save time compared to conventional washing. For every applied wash (light wash, med wash, dark wash), we can save 20 min for each wash if we work with sustainable wash types and recipes. Whereas conventional (light wash, med wash, and dark wash) need 124,129,129 min for washing. On the other side, sustainable washing (light wash, med wash, and dark wash) needs 104, 109, and 109 min for washing (Fig. 14).
Comparison of the time impact of conventional and sustainable denim wash
Comparison of the water impact of conventional and sustainable denim wash
3.3 Impact of water
Sustainable wash requires 7.8 (L/clothing) for light wash garments, 2.55 (L/garments) for mid-wash garments, and 8.1 (L/garments) for dark wash garments. Conventional wash requires 9.9 (L / garments) for light wash garments, 11.4 (L / garments) for med-wash garments, and 14.1 (L / garments) for dark wash garments. As a result, conventional light wash wasted an additional 2.1 (L / garments), while medium and dark conventional wash wasted 8.85 (L / garments) and 6 (L / garments) respectively (Fig. 15).
3.4 Energy impact
Sustainable washing requires 0.64 (Kwh/garment) of energy for light wash garments, 0.64 (Kwh/garment) for mid-wash garments, and 0.64 (Kwh/garment) for dark wash garments. In contrast, normal washing requires 0.25 (Kwh/clothing) energy for light wash garments, 0.45 (Kwh/garments) for med wash garments, and Energy consumption for dark wash clothing is 0.45 (Kwh per garment). Finally, we require 0.39 (Kwh/garments) + 0.19 (Kwh/garments) + 0.19 (Kwh/garments), for a total of 0.77 Kwh extra energy if we use sustainable wash for each wash type: light wash, medium wash, and dark wash (Fig. 16).
Comparison of the energy impact of conventional and sustainable denim wash
3.5 Chemical impact
Sustainable wash requires 33.5 for light wash garments, 38.5 for med-wash garments, and 33.5 for dark wash garments. In contrast, traditional washing requires 49.5 for light wash garments, 59.5 for med-wash garments, and 54.5 for dark wash garments. By using sustainable wash, can save 16 on light wash garments, 21 on med-wash garments, and 21 on dark wash garments. Every sustainable wash helps to reduce chemical waste. It will help to address our environmental safety concerns (Fig. 17).
Comparison of the chemical impact of conventional and sustainable denim wash
3.6 Worker impact
The table explains the worker impact of sustainable wash needs. 29.5 for light wash garments, 34.5 for med-wash garments, and 32 for dark wash garments. Conversely, conventional wash needs 51 for light wash garments, 57.5 for med-wash garments, and 55 for dark wash garments. So that can save 21.5 for light wash garments, 34.5 for med-wash garments, and 23 for dark wash garments by applying sustainable washing (Fig. 18).
Comparison of the worker impact of conventional and sustainable denim wash
3.7 EIM score impact
1–33 score is low impact, 34–66 score is medium impact, out of range like, up to 66 score is made a high impact. Every sustainable wash has a low impact score, which is 29 for a light wash, 32 for med-wash & 30 for a dark wash. So each wash will not pose a threat to our environment. On the other side, every conventional wash makes a medium impact score, which is 45 for a light wash, 49 for med-wash & 48 for a dark wash. That's why it will harm our environment (Fig. 19).
Comparison of the EIM impact of conventional and sustainable denim wash
3.8 Wash cost
Each environmentally friendly wash is very considerate of both the environment and the production process. Customers usually disagree with the sustainable wash, nevertheless, because of its price point. When evaluating our ecologically friendly production, the cost must be taken into account. Superior chemicals, knowledgeable labor, freshwater, eco-friendly practices, and other elements all affect pricing.
The following table represents a comparative chart between the current study and similar previous research work (Fig. 20).
Comparison of the wash cost of conventional and sustainable denim wash
4 Conclusion
The denim jacket is used to conclude this research. The denim jacket is made of 100% organic cotton. In this study, we attempt to highlight the denim industry, denim's forthcoming process (the sustainable wash process), and denim's conventional method while contrasting the conventional wash with the sustainable wash. The text compares and evaluates processes contributing to environmental pollution in denim, highlighting the industry's economic contribution and the need for sustainable denim wash. It emphasizes the importance of adopting a sustainable development strategy for a promising future of denim.
-
Time Efficiency Sustainable washing saves at least 20 min per wash compared to traditional methods.
-
Water Usage Conventional washing uses more water, with light washing wasting an extra 2.1L per garment and mid and dark washes wasting 8.85L and 6L more than sustainable methods.
-
Energy Consumption Energy consumption is higher in sustainable washing at 1.92 Kwh/garment, compared to 1.15 Kwh/garment in conventional washing.
-
Chemical Usage Sustainable washing reduces chemical usage, saving 16, 21, and 21 points on a chemical impact scale for Light, med, and dark washes, respectively.
-
Worker Impact Worker impact is also lower in sustainable washing at 96, compared to 163.5 in conventional methods, resulting in a saving of 79 points.
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EIM Score The EIM score is lower in sustainable washing (29 for Light, 32 for med, and 30 for dark wash) compared to conventional methods (45 for Light, 49 for med, and 48 for dark wash).
This study suggests that sustainable washing is more environmentally friendly and efficient. It’s a great reminder of how small changes in our daily routines can have a significant impact on the environment.
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Khondoker, B., Shoukat, S., Malitha, S.B. et al. A comparative study between conventional & sustainable wash by the application EIM software & wash cost: an approach of environmental sustainability aspects. Environ Dev Sustain (2024). https://doi.org/10.1007/s10668-024-05120-4
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DOI: https://doi.org/10.1007/s10668-024-05120-4