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Technology

CleanKore
Patented Ring Dyeing Technology

CleanKore reduces process energy demand by eliminating the need for the hazardous potassium permanganate spray, reducing chemical usage and overall production time. CleanKore utilizes denim mill's existing dye range and makes novel modifications to produce a ring-dyed effect with a large white core with a small perimeter of dye. This solution lowers the carbon footprint without adding any new chemicals or capital expenses/equipment. Applicable from indigo to sulphur black.

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Solution tier focus

Patented Ring Dyeing Technology focuses on Tier 2.
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Tier 4
Raw material extraction
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Tier 3
Raw material processing
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Tier 2
Material production
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Tier 1
Finished product assembly

Solution maturity level

Pre-seed

Definition:
Solutions that are at a concept level and in the process of evaluating and establishing their impact potential.

Pilot

Definition:
Solutions that are in the process of testing their solution in order to demonstrate a proof of concept.

Model

Definition:
Solutions that are working towards de-risking and reducing known barriers to scale.

Scale

Definition:
Solutions that are commercially viable with a proven go-to-market strategy.
Goal:
Develop more sustainability studies in each region to target key denim brands, denim retailers and garment manufacturers.
Scale
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Current Level
Pre-seed
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Pilot
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Model
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Scale DEFINITION
Solutions that are commercially viable with a proven go-to-market strategy.
swirls graphic blueLEARN MORE ABOUT OUR MATURITY LEVELS
Current Level
Goal Of This Scale Solution
Develop more sustainability studies in each region to target key denim brands, denim retailers and garment manufacturers.
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Pre-seed DEFINITION
Solutions that are at a concept level and in the process of evaluating and establishing their impact potential.
LEARN MORE ABOUT OUR MATURITY LEVELS
swirls graphic blue
Pilot DEFINITION
Solutions that are in the process of testing their solution in order to demonstrate a proof of concept.
LEARN MORE ABOUT OUR MATURITY LEVELS
swirls graphic blue
Model DEFINITION
Solutions that are working towards de-risking and reducing known barriers to scale.
LEARN MORE ABOUT OUR MATURITY LEVELS

Location Availability

CleanKore is currently implemented at 30 denim mills across the world - including Bangladesh, China, India, Pakistan, Turkey - and can be applied in all regions.
5
Available regions
30
Sites
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Actual Solution impact

Impact is calculated over the duration of the solution.
What are the different saving types?
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GHG savings
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0.77–0.87
kgCO2e
Average actual savings per kg of production
31-67% Average
Energy savings
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9.9–11.23
MJ
Average actual savings per kg of production
31-67% Average
Water savings
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536,750
M3
Average actual savings per site/year
33.00% Average

Financial breakdown

There is a one-time cost for the development of the process. Following that, there is a royalty fee for using the process. This is costed on a per yard basis. CleanKore receives the royalties based on the yards of fabric produced through CleanKore sold.
Site Investment
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Implementation cost
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3
Payback period
Average payback in months
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The average length of time required for an investment by a site to recover it's initial outlay in terms of profits or savings.
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1
tCO₂e =
$16
$67 industry average
Payback period
Average actual total investment cost per tCO₂e reduction
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The cost per tonne of CO₂e reduced as a result of the solution(s) over the useful life of each project, including brand and site program contributions, as well as all implementation costs.

Invested COST PER tCO₂e

DISCLAIMER: These are average projected values, average cost and impact ratios will depend on site specific implementation.
What are the different saving types?
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Implementation Plan

CleanKore provides CleanKore Specifications to the mill for changing the conventional fabric dyeing. CleanKore provides washing recipes to match the target wash aesthetics with the reduction of resources and elimination of hazardous chemicals. The mill and garment factory need to follow the CleanKore Specifications and recipes.
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1 month
Projected project length
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Implementation milestones
Once CleanKore licensed, mills join a global network of mills that produce fabrics, from open end to ring-spun and from pure indigo to sulphur black denim.
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1
Sign Non-Disclosure Agreement
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Mill partner provides current dyeing specifications
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CleanKore provides mill partner with CleanKore dyeing specifications of same product
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CleanKore attends mill trials either in-person or online
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Mill sends fabric to CleanKore for testing to verify results
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Fabric shipped to the garment manufacturer
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CleanKore works with garment manufacturer to provider shorter, leaner washing and finishing recipes to maximize sustainability
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Example projects
The CleanKore Technology can be implemented for Indigo and Sulfur Dye applications on Cellulosic yarns on Continuous Warp Dyeing Machines like Slasher and Rope. The Indigo and Sulfur Dyes have different dyeing conditions. The Indigo is applied at room temperature while the Sufur dyes are applied between 80 to 95 °C. The dyeing auxiliaries are different for Indigo and Sulfur Dyes. Hence, the CO2 emission is different for Indigo and Sulfur Dyeing.
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BluWin Case Study

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2 Regions
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3 Sites
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1 Month

Impact

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GHG saved
96,750
tCO2e
Energy saved
30,600
GJ
Water saved
536,750
m3

The Challenge

CleanKore appointed BluWin to conduct and validate the comparative savings throughout the supply chain with using traditional vs CleanKore fabrics. Both indigo and black fabrics were chosen for the case study to show the benefits of CleanKore throughout all fabric ranges and washes. BluWin mapped traditional vs CleanKore dyeing at the denim mill and the fabric for garment washing. Traditional fabric in indigo and black went through standard wash recipes, while CleanKore fabric had lean, reduced recipes.The savings below maps the full sustainability achievement throughout the denim supply chain.

Read more case studies
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Solution technology growth

Since 2020, Patented Ring Dyeing Technology has been deployed in over 30 sites, resulting in a total investment of $500,000

30

Total sites

2020–2023

14

Brands adopting this solution

2020–2023

$500,000

Actual total investments

2020–2023

Solution providers

CleanKore

Our patented technology makes unique modifications to the dye range to preserve the natural white core of the yarn. This results in the elimination of potassium permanganate and the reduction of GHG emissions, water, chemicals, and energy throughout the supply chain at cost-neutral or cost savings without any new chemicals or equipment.

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Interested in this solution?

Get in touch to learn more about how to implement this solution
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