U.S. Denim’s Rapid Clean Tech Produces Authentic Looks with Less Impact
Many of the processes used to create the iconic look and feel of denim are resource intensive and polluting. Pakistan-based U.S. Denim is tackling the environmental impact of finishing with its Rapid Clean technology, which makes the process both more sustainable and speedier. The technology improves the fabrics’ laser response and leads to quicker washdowns.
Rapid Clean can be used on both blue and black denim, and fabrics finished with Rapid Clean come out cleaner and brighter. Black overdyed fabrics often have a reddish, pale look, but this technology enabled U.S. Denim to make a jet-black shade.
By using the Rapid Clean process on Lenzing fibers, U.S. Denim can create fabrics with the classic denim look that are also super soft. “Nowadays mostly customers are looking for authentic fabrics with added comfort and premium hand feel,” said U.S. Denim.
The mill spoke to Carved in Blue about its technology and its overarching approach to sustainability.
Carved in Blue: What is the sustainable denim trend in focus?
U.S. Denim: Right now, there are two different kind of sustainable denim trends. First is the process innovation with respect to sustainability, like our Rapid Clean technology and Eco Zero process, which offers up to 90 percent water savings in the dyeing process. The second one is the fibers like recycled cotton and sustainable biodegradable fibers, which have a tendency to make good soft comfort fabrics as well as vintage authentic looks. Yes, cotton tradeoff is still there as cotton is not able to sustain the load alone. Also, its production is decreasing year by year, so it must need other cellulosic fibers to share the market.
Carved in Blue: What is the story behind your Rapid Clean technology?
U.S. Denim: Rapid Clean is an eco-efficient alternative technology for some of the most water-intensive and pollutant fabric finishing processes. It allows us to save natural resources in a numerous amount, ultimately playing its part in reduction of GHG emissions.
Carved in Blue: How does Rapid Clean work?
U.S. Denim: Rapid Clean is basically an alternate to the regular fabric finishing processes in which extensive use of water is involved. Instead we use a process to eliminate the hue and make the fabric look cleaner.
In this process, we achieve 63 percent water savings, 32 percent steam savings and 33 percent GHG savings.
Carved in Blue: Does that have an influence also wearing the garment from raw and having a faster customized look?
U.S. Denim: Yes, it has beautiful impact on aesthetics starting from raw and goes down to the washes. On raw, it has a beautiful hueless, cleaner look, and in the lighter washes, the shade chip off is really quick. Secondly, the washes are very unique and bright; they are not on the paler or greyer side.
Carved in Blue: Is there any IP protection involved?
U.S. Denim: No there is no IP protection involved, we have just created this process and we are open with our customers to share this technology.
Carved in Blue: How is the reaction from the customers to Rapid Clean so far?
U.S. Denim: Rapid Clean is just like a shining star to us. It has added magnificent properties to the fabric like sustainability, hueless looks, quicker shade chip off that saves time and resources to the garment manufacturer and brighter and cleaner wash downs.
It is very well appraised by the brands and customers.
Carved in Blue: How you combine TENCEL™ fibers into your sustainable concepts?
U.S. Denim: We have designed some new products with Lenzing fibers like TENCEL™, matte TENCEL™ and ECOVERO™ to make amazing products in which some are super authentic and some are cotton-free comfort fabrics with very smooth and soft touch. When we combine Rapid Clean with the Lenzing products, this idea is a win-win situation for everyone. The product comes out to be super amazing, sustainable and has a very premium hand feel.
Carved in Blue: What is the sustainable journey of your company?
U.S. Denim: The sustainable journey started some decade back, but in 2019 we set a nine-point sustainability agenda for next three years called “Sustainability Challenge 2022.” The major points were:
- Health, safety and well-being
- Greenhouse gas emissions
- Energy management
- Renewable energy
- Water management
- Chemical management
- Waste management
- Materials and technology
- Gender diversity
We have successfully achieved our goals for 2022, and now we are working on sustainability challenge 2025.