Green Dye is a new cutting-edge dyeing technology developed by Karl Mayer, a pioneering force in textile machinery. This innovation enables indigo dyeing in the denim industry by replacing conventional methods with an eco-friendly and efficient approach. GreenDye takes dyeing to a new level by fine-tuning the application process and significantly reducing waste, ensuring a lighter footprint on our planet. It was introduced at ITMA 2019 and after that several major denim brands have adopted the technology.
The main basis of Green Dye is the use of nitrogen (NOX) technology to control the chemical dyeing process. It is two times cleaner and at the same time three times more efficient than the processes of conventional dyeing techniques. In the NOX reactor, the nitrogen atmosphere temporarily inhibits the oxidation of indigo dye, providing a crucial window for the dye to form a strong physical bond with the fibers. This enhances both the adherence and more permanent fixation of the dye.
Advantages:
- A yarn can absorb three times more dye compared to conventional methods.
- Significant reduction in the number and length of dyeing vats needed.
- Use of hydrosulphite and caustic soda can be decreased by 50%
- Less waste of yarn during the dyeing process.
- Use of considerably less water during the subsequent washing process.
In addition, this system has very low operating costs, requiring less space and maintenance than traditional dyeing systems, along with saving time and spare parts for the same output.