From its new plant in Mexico, Archroma offers regional textile manufacturers an Indigo Denisol® supply source close to its final market.
TW Special Report
Switzerland-based Archroma — a manufacturer of dyes and specialty chemicals for sustainable solutions — started operations at its new plant in Mexico last January. The plant’s main production is Denisol® Indigo pre-reduced liquid used in the textile industry.
Located in Salvatierra, Guanajuato, this is the third Archroma plant in Mexico that provides service to textile manufacturers in the country as well as other Latin American markets; and it is the only indigo plant available in the region. For local manufacturers, the fact that there is now a plant in Mexico is a competitive advantage since they have a supply source close to their final market.
Archroma launched Denisol Indigo liquid into production in 2015, in Jamshoro, Pakistan. There, the company has implemented a zero liquid discharge operation to preserve the water in the area, in accordance with the company’s approach to sustainability and natural resource preservation.
Archroma continuously challenges the status quo in the deep belief that it can make the industry more sustainable.
In line with this mission, the company is following a clear agenda — convert denim dyes in the Latin American region and around the world to Denisol Indigo liquid instead of indigo powder in the dyeing process, which will lead to massive reductions in the use of indigo dye itself, as well as sodium hydrosulfite and caustic soda.
An estimated 65 percent of the denim industry still uses indigo powder and Archroma’s denim specialists are focusing on transforming this into liquid pre-reduced indigo, and as a result being able to reduce the impact on the environment.
Archroma has become a specialist in ecologically advanced denim fashion colors and designs with its unique offerings. Solution systems and technologies are available to denim manufacturers and brands featuring Denisol Indigo liquid. Denisol is used in Archroma’s
CLASSIC INDIGO FLOW system. Its Diresul® Smartdenim Blue, a blue liquid sulfur dye designed to imitate a neutral greenish blue color, features in Archroma’s INDIGO REFLECTION. Both Denisol and Diresul feature in CLASSIC UNDERTONES, a sulfur bottoming system that brings a new layer of color creativity to indigo denim.
“With the growing consumer awareness and the demand for ecological and sustainable fashion, textile manufacturers are exploring new clean ways to produce and dye denim,” said John Jansen, Archroma commercial president for the Americas. “This is where Archroma can add value with innovative solutions, as well as color systems, and creative and avant-garde denim effects. With our indigo plant in Guanajuato, Mexico, we are providing our customers through the American continent a supply source of indigo, closer to their final market allowing them to accelerate delivery times in an industry where the speed of updates is critical.”
Although Archroma has not shared information about the investment in the Guanajuato, Mexico, plant, the company shows interest in the country where it seems it will continue investing in the medium- and long-term because Mexico is one of the main denim manufacturers in Latin America with production of approximately 300 million fabric meters per year. For this reason, Archroma sees great potential for the dye supply for the denim treatment which also will contribute to a decline in imports from China.
In addition, the Mexican market is very important for Archroma’s textile operations, representing between 25 and 30 percent of the income from its Americas region.
About Indigo Denisol® Pre-Reduced Liquid
Denisol Indigo is a pre-reduced indigo solution at a 30-percent concentration. The company reports it is easy to use, and allows high reproducibility and deep shades while reducing impact on wastewater compared to indigo powder.
It is compliant with major official eco-standards and requirements from retailers, brands and leading fashion companies and helps to produce fabrics suitable for current eco-labeling.
Some of the reported advantages of Denisol liquid compared to indigo powder are:
- Chemical consumption: Stock vat preparation is not needed, therefore less sodium hydrosulfite and sodium hydroxide are used.
- Sustainability: Reduced impact on wastewater treatment plant including chemical oxygen demand, biological oxygen demand, sulfates and sulfites, and total dissolved solids.
- Easy handling: Automated dosing allows for a simpler handling process.
Regarding technical advantages, Indigo Denisol Liquid offers:
- Increase in productivity with less indigo required to achieve the same depth of shade;
- Better shade consistency and reproducibility, and higher color yield achievable; and
- Improved rubbing fastness on dark tones.
For all these advantages and for being a sustainable solution, Denisol Indigo pre-reduced liquid has received the Cradle to Cradle Products Innovation Institute’s Gold Level Material Health Certificate.
Innovation In Dyeing
Pretreatment is indeed a key step in textile production and the diversity of fibers and quality variations are major challenges in consistently obtaining a perfectly prepared fabric ready for subsequent processing steps.
Archroma’s portfolio offers wide possibilities in dyeing effects and colors, from the traditional to innovative, while maintaining high standards of quality and sustainability. Its products are designed to address the specific dyeing requirements of all types of effects.
Denim is one of the textiles of greatest interest to the company, and Archroma has made a number of contributions to the denim industry with cutting-edge dyeing technologies and products that bring together creativity, performance and sustainability — as is illustrated by its Denisol Indigo pre-reduced liquid.
Using Archroma auxiliaries for indigo dyeing, customers can improve the consistency and the workability of the dyeing process, which will result in a high level of quality, according to the company. Customers also can achieve a uniform, level dyeing appearance, as well as reduced staining on indigo dyeing machinery, according to the company.
With its production at the Guanajuato plant, Archroma confirms its commitment to the success of the textile manufacturers in the region by offering them a higher-performance solution that reduces costs and at the same time allows manufacturers to have a lesser impact on the environment.
The company’s focus remains on making the textile industry a sustainable activity, both economically and ecologically.