Industry Experts Weigh in on Winning Water-Saving Solutions
Water is one of the most precious natural resources, but the industry hasn’t always treated it kindly. Following wakeup calls about the waste and scarcity that stem from water-intensive processes, denim makers are developing methods that reduce their water impact.
Carved in Blue asked industry insiders to share what technologies they feel have been most impactful. Read part two of this series—featuring executives from Another Design Studio, Kipas Denim and The Lycra Company—below for insights on what is driving progress.
Mustafa Guleken, general manager, Kipas Denim
One of the most impactful water-saving methods I have seen in the denim industry is the implementation of an automation-based system integrated into traditional indigo rope dyeing machines. This innovative approach dynamically optimizes water flow in each stage of the process—pre-wash, indigo dyeing and post-wash—by utilizing sensors and a PLC [programmable logic controller]-controlled system that adjusts water usage based on real-time production parameters.
This system reduces water consumption significantly—by approximately 62 percent, from around 40 liters per kg to 15 liters per kg of yarn—by precisely controlling water flow in each process stage rather than relying on fixed, excessive water amounts.
This leads to a number of benefits. There is a dramatic reduction in water use, leading to environmental conservation. It lowers operational costs due to decreased water and chemical consumption. It also improves process control and consistency in product quality. Additionally, there is a reduction of wastewater generated, decreasing treatment costs and environmental impact.
This technological innovation supports sustainable denim production by minimizing water footprint and promoting resource efficiency. Its successful integration demonstrates a scalable solution for the textile industry that aligns environmental responsibility with economic benefits, paving the way toward more sustainable manufacturing practices.
Ebru Ozaydin, global product category director, denim, wovens and RTW, The Lycra Company
According to European Circular Economy Stakeholder Platform, the textile industry consumes 93 billion cubic meters of water annually, with dyeing and finishing being the main culprits.
Jeanologia and Tonello are leading the charge in revolutionizing denim washing with their innovative water-saving strategies, crucial for reducing the environmental impact of the textile industry. Both companies are setting new benchmarks in denim washing, focusing on closed-loop water systems, resource optimization and minimizing chemical usage. Their strategies are vital for the denim industry’s sustainability, promoting significant water conservation, thus contributing to a more eco-friendly and responsible production process.
Jeanologia’s Mission Zero initiative aims to drastically reduce water consumption and chemical use in denim production. Supporting this, Jeanologia’s Environmental Impact Measurement (EIM) Score objectively assesses the environmental footprint of garment finishing in terms of water, energy and chemical use, promoting more sustainable production decisions. Their G2 Technology (also used in fabric finishing), as well as Atmos are all ground-breaking innovations. We collaborated with Jeanologia for a project called “Oneness: Americas for the America”in 2024 with Global Denim Mexico that incorporates technologies from The Lycra Company, including Lycra dualFX and Lycra lastingFit fabrics, as well as Coolmax and Thermolite fiber technologies.
Tonello’s All-in-One System is also another smart and efficient garment wash innovation that integrates multiple advanced technologies to reduce water, energy and chemical use. The versatility and the flexibility help the makers to optimize the savings.
Stefano Aldighieri, president, Another Design Studio
Over the last few years, we have seen a proliferation of wild claims made by brands and retailers, concerning “huge savings” in water consumption. Headlines like “saving 20 percent of water,” or even more, without providing any clear, factual data (20 percent off what?). Given that there is no widely accepted standard measurement of how much water is actually used to produce a pair of jeans, all these claims are baseless and can be described as pure greenwashing.
Of course, water usage is a big concern; one of the craziest facts in our industry is that mills, factories and laundries seem to be mostly located in countries and areas that have serious water shortage issues.
It is great to see many machine producers develop new technology that somewhat helps reduce the amount of water needed in dyeing, washing, etc., and many mills and laundries have adopted them, at great cost—nobody is willing to recognize that making these positive changes does not come free.
As good as many of these initiatives are, the main limitation, in my opinion, comes from the fact that all these will still use large amounts of water—nobody can come up with a way to produce without it; the next best thing is to only use recycled water. There are systems out there that will process all the water used in the industrial process and put it back into circulation. Some of these can take sewage water from the local community, treat it, use it in their manufacturing, treat it again and reuse it; excess water can be sent back to the local water system, clean and potable.
I believe this is the only truly viable solution. Instead of focusing on “small” reductions, just eliminate the need for fresh water to begin with. Every mill and every laundry in the world should be equipped with effluent treatment plants, which can filter and process—without the use of chemicals—all the water they need. If that happened, why should it matter how many liters of water are required to make denim?
Why is this not happening on a large scale? Because investing in these technologies requires investments, and brands and retailers are not interested in actually supporting real tangible efforts, if it means an even small increase in the COG [cost of goods]!
As usual, unless governments introduce legislation to concretely support the adoption of ETPs by manufacturers and start giving fines to brands and retailers who do not comply, things will not change. Very few will do it just because it is the right thing to do!
Read part one of this series here.