Manufacturers can now make ‘green’ jeans

Making denim results in significant water and air pollution.
Image: FreeDigitalPhotos

Every year approximately 2 billion jeans are made worldwide. 

The manufacturing of just one pair of jeans entails the use of 2,500 gallons of water, one pound of various chemicals and a whole lot of energy. It is therefore no surprise that the denim industry contributes a great deal to both water and air pollution.

 

At a recent Green Chemistry and Engineering Conference, however, a more eco-friendly manufacturing process was introduced. 

The Advanced Denim process offers several alternative options during production. Jeans can now be made with 92 percent less water and 30 percent less energy. The amount of cotton waste can be reduced by 87 percent and instead of using 15 dyeing vats full of harmful chemicals, this new process uses only one vat and replaces harmful chemicals with more eco-conscious liquid sulfur dyes.

The history of denim-making

Denim is made from a rough kind of cotton called rugged cotton twill. Up to 10 percent of the world's pesticides are used for treating cotton. Literally tons of water is used to grow the raw material. And in order to make denim what we know it to be, indigo dye is used to color the jeans blue. 

Today, indigo dye is, for the most part, produced synthetically. Chemicals, such as aniline, formaldehyde, hydrogen cyanide and sodamide are used to make the dye, all of which can have negative health effects. Some are skin and respiratory irritants, while others are carcinogenic.

Studies have lead scientists to believe that if the Advanced Denim process was used to produce only 25 percent of the jeans made worldwide, 1.7 million people would have their water needs met every year. In addition, 220 million kilowatt hours of electricity would be saved, reducing corresponding carbon dioxide emissions.

Is it surprising to know how many jeans are made every year?  What do you think about this new Advanced Denim process?

Source: ACS

Improving air quality within manufacturing facilities

The RAP series is just one of
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for chemical plants

Though there are many benefits to using this new Advanced Denim process, it will take time for companies to apply this system to their factories. In the meantime, a lot of harmful chemicals are used to make the blue dye we so love in jeans.

It is the companies’ responsibility to ensure their employees are working in safe environments and good indoor air quality is part of that health and safety. As long as chemicals are used, chemical exposure and fumes are a risk. It is in the best interest of the companies to provide an air cleaning solution which will keep employees breathing easy.

Electrocorp manufactures air cleaning units for the industrial sector. Our units can range from small air cleaners which can be placed close to the source of the harmful chemicals or fumes, to large units that can be attached to an HVAC system, cleaning the entire central air system.

To find out more about our air cleaners, contact us or speak to one of our IAQ experts at 1-888-667-0297.

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Denim dyes in need of “green” makeover

The denim dying process involves
many chemical reactions.
Photo: Worakit Sirijinda

Indigo may be called the “king of dyes”, but the denim dying process is wasteful and may expose workers to potentially harmful fumes and chemicals.

While currently 50,000 tons of indigo are used to color cotton blue jeans and other products, scientists are looking for more environmentally friendly ways to dye denim.

Indigo has been used for centuries and used to be harvested from a bush native to India. Indigo can dye products in a range of hues, from deep navy blue to pale pastels.

Chemists discovered a method to manufacture the dye, which is used all over the world.

However, the dying process produces large amounts of waste and requires chemical reactions before and after the dye impregnates the cotton fibers get a lasting dye job on the fabric.

Now, two companies are working together to try and come up with a greener process to dye denim. They are trying to eliminate the use of sodium hydrosulfite in the process, which also causes water pollution.

An article in the American Chemical Society’s weekly news magazine Chemical & Engineering News describes the efforts.

Source: American Chemical Society

Protect workers from chemical fumes and gases

Whenever chemical reactions are required in a manufacturing process, there is a chance of chemicals and fumes in the ambient air.

Even traces of those chemicals may have an effect on the workers' health and well-being and should be filtered out.

In addition to source control and proper ventilation, an industrial-strength air cleaner with activated carbon and HEPA filters can help remove pollutants from the air.

Electrocorp offers portable and customizable air cleaners for industrial and commercial applications that can help remove airborne chemicals, gases, fumes, odors, particles, dust, bacteria, viruses and mold, among others.

Electrocorp has designed air cleaners for chemical processing plants as well as for effective chemical and odor control.

Contact Electrocorp for more information and options.