Spray Dyeing on slasher dyeing ranges - Apparel Impact Institute

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.

Goal:

Expand the commercial adoption of RotaSpray spray-dyeing technology in denim sheet yarn dyeing facilities globally, focusing on reducing chemical consumption, thermic energy consumption, and GHG emissions while improving process efficiency.

Scale

Definition:

Solutions that are commercially viable with a proven go-to-market strategy.

Model

Current Level

Pre-seed

Pilot

Scale

Model DEFINITION

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

LEARN MORE ABOUT OUR MATURITY LEVELS

Goal Of This Model Solution

Current Level

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

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

Scale DEFINITION

Solutions that are commercially viable with a proven go-to-market strategy.

LEARN MORE ABOUT OUR MATURITY LEVELS

Financial breakdown

Rota Spray retrofits in existing sheet dyeing range is an equipment upgrade for product improvement by process change. The tentative cost factors include machinery cost, possible modifications to the main dyeing line, annual maintenance and spare parts.

Site Investment

Implementation cost

Payback period

Average payback in months

tCO₂e =

$67.93

$67 industry average

Payback period

Average actual total investment cost per tCO₂e reduction

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?

Implementation Plan

The process involves contacting denim mills though various sales and marketing channels to propose retrofit solutions. We analyze the dyeing line's layout, discuss advantages, savings, and projected ROI to ensure a customized approach. Subsequent steps include pre-installation training, customer self-installation, startup by WEKO, process training and trials and finally reviewing progress after a month.This efficient process allows denim mills to improve quality, lower costs, achieve positive results and environmental savings.

9 months

Projected project length

Implementation milestones

Projected project length

Lead generation

Project technical clarification and scopes

Quotation and order

Pre installation training

Customer self installation

Startup, process training and trials by WEKO

Review and follow up

Example projects

Re-use of baths, residual liquors or cooling water
Re-use of steam condensate
De-watering before drying
Replace overflow rinsing
Minimize re-dyeing ratio

Case Study

1 Region

1 Site

1 month

Impact

GHG saved

tCO2e

Energy saved

1000

Water saved

105

The Challenge

A case study was conducted on the denim yarn sheet dyeing process at a denim mill in India. Traditional denim yarn sheet sulfur dyeing follows a sequential process: prewetting, washing, sulfur dyeing in dye boxes, steaming, oxidation, neutralization, washing, and drying. In contrast, the Rota Spray dyeing method bypasses the conventional slasher dye boxes entirely — after prewetting and washing, the yarn sheet passes directly into two Rota Spray boxes where the dye bath is applied by spray. All post-dyeing steps remain identical to the traditional process.

Solution providers

WEKO

WEKO, Weitmann & Konrad GmbH & Co. KG, is a well-known German engineering company that specializes in high-precision, contactless application technologies for liquids and powders. Headquartered in Leinfelden-Echterdingen near Stuttgart, the company has been innovating in industrial process optimization since 1953. WEKO’s rotary atomizer spray technology allows precise and uniform application while using less water, chemicals, and energy. Key innovations include Rota Spray dyeing for efficient and sustainable dye application in woven textile fabrics and denim slasher yarn. WEKO serves various industries, enhancing product quality, process efficiency, and environmental sustainability, while supporting global manufacturers in achieving resource-efficient production.

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