The Innovations Behind SM Denim’s Dyeing and Weaving Patents
Ingenuity and innovation are two core pillars of Karachi, Pakistan-based manufacturer SM Denim, and this investment in research and development has led to two new patented processes.
Tackling water consumption in denim dyeing, the mill created the newly patented IndiCan method that uses cationic and anionic polymerization to improve dye fixation. Green chemical compounds are applied to the cotton before dyeing to prepare the fibers, create better color retention and reduce bleeding. IndiCan also improves colorfastness by applying a protective second coat of dye that prevents colors from fading or washing off.
Denim production typically uses considerable water, and it is a main contributor to industrially created pollution. In conventional dyeing, about 15 percent of dyestuff washes off. Comparatively, IndiCan has a 100 percent fixation rate. Because the color penetrates and locks on to the fibers better, dyestuff doesn’t end up contaminating the water used for dyeing.
Compared to conventional dyeing methods, IndiCan offers a 71.9 percent water savings and 70 percent lower energy usage. IndiCan also uses to 30 percent less dyestuff.
The resource savings also happen at the finishing level, with reductions in chemicals, steam and water. One of the contributors to this is the elimination of desizing, or the removal of sizing compounds applied prior to weaving.
“We are thrilled to receive this patent, which validates our commitment to innovation and sustainability,” said Asif Merchant, CEO of SM Denim Mills. “The IndiCan process not only revolutionizes textile dyeing but also aligns with our goal of reducing environmental impact. This breakthrough underscores our dedication to leading the industry toward a more sustainable future.”
SM Denim has also successfully applied for a patent for a fabric weaving method that produces dobby-style patterns on air jet looms. Enabling the creation of complex and varied patterns on air jet machinery is a new shedding mechanism. With this loom swap, the fabrics created are softer and stretchier. This also creates more production efficiency with a shortened setup time.
“We are thrilled to receive this patent, which underscores our commitment to innovation and excellence in textile manufacturing,” said Asif. “This breakthrough will enable us to offer our clients fabrics with unmatched quality and distinctiveness.”