US Denim Mills Develops Rapid Clean Manufacturing Technology – Sourcing Journal

A sustainable mindset has become an imperative business requirement today, putting a lot of pressure on manufacturers to innovate eco-friendly manufacturing techniques at every possible stage.

In a nod to the growing demand for sustainability in apparel manufacturing, Pakistan-based US Denim Mills, the US group’s textile vertical, has developed Rapid Clean, another eco-efficient alternative technology that increases efficiency, reduces resource depletion and costs. Waste—all while increasing customer satisfaction.

Rapid Clean is a sustainable manufacturing technique designed to replace the most water-intensive and polluting fabric finishing processes. This smart technology by US Denim Mills allows the company to conserve natural resources, ultimately playing its part in reducing greenhouse gas (GHG) emissions. This process curates premium quality denim fabrics that the manufacturer calls “immaculate look and feel.”

“US Denim Mills’ Rapid Clean Technology represents our hands-on approach of choosing technological innovations to redefine denim in a more sustainable way,” said Moin Akram, US Group Director of Marketing and R&D, Denim Mills. “This technology is effective in producing sustainable, laser-adaptive denim fabrics with minimal resources and opens up new horizons for design. This concept also enables us to produce black overdyed fabrics, which tone down faster and brighter than traditional fabrics, such as undyed black denim.

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US Denim Mills says the aesthetics of the fabrics developed with Rapid Clean Technology are revolutionary in maintaining the fiber’s diversity and eco-friendly nature.

What makes Rapid Clean different? Denim fabrics developed using this technique are clean, shiny and soft. According to the denim manufacturer, fabrics finished using the technology have the ability to achieve these desired results better than the traditional process.

Its efficient features help to reduce garment finishing time, as the process improves the denim’s ability to adapt to lasers and supports faster washing, thus reducing water and energy used in the process.
The rapid clean technology features make the solution ideal for key denim fabric colors (blue and black), says the denim manufacturer.

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US Denim Mills wants this technology to usher in a new era for overdyed fabrics, which are denim fabrics that have been previously dyed through another round of dyeing. While traditional overdyed fabrics tend to be more on the lighter side with a red tone, US Denim Mills has achieved a jet black shade using Rapid Clean technology. This not only reduced the red cast of the jeans, but also made for much faster and brighter washes.

Comparison between traditional black fabric and US denim’s Hueless Black

Rapid Clean was able to significantly reduce resource flow throughout the washing, de-sizing and overdying processes.

Washing with Rapid Clean technology saves 63 percent more water and 32 percent more steam than the traditional process, while reducing GHG emissions by 33 percent.
During de-sizing, the technology enables US Denim to save 75 percent more water and 47 percent more team, while reducing GHG emissions by 47 percent.

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Finally, using Rapid Clean in the overdying process saves 80 percent more water and 75 percent more steam, reducing GHG emissions by 74 percent compared to the traditional process.
The Research and Development (R&D) team at US Denim Mills, guided by the mantra of “Inclination to Innovation,” is always driven to bring out technological and manufacturing excellence that reduces the burden on the Earth’s resources. In pursuit of that, US Group will continue to serve fashion and industrial needs with more innovative projects designed to make products durable, subtle and authentic.

US Denim Mills’ Smart Rapid Clean Technology offers production methods that curate eco-friendly products to meet contemporary demands.

The pinnacle of the US group’s success lies in promoting sustainable fashion, which not only supports the company’s commitment to conserving the Earth’s depleted resources, but also provides a greener mindset by changing the mindset of generations to come.

Learn more about US Denim Mills and the US Group here.


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