AVITERA® SE: Sustainability step-change in cotton dyeing

First innovative para-chloro-aniline (PCA) free* reactive dye range delivering economic and environmental sustainability to mitigate the textile industry’s toughest challenges

As a leading global dyes and chemicals manufacturer, Huntsman Textile Effects is well recognised in the market as an innovator and collaborative leader in the textile sector. Its new breakthrough, the groundbreaking AVITERA® SE range of dyes, is another global game changer, helping the industry become more sustainable.

The first reactive range of dyes free of para-chloro-aniline*, AVITERA® SE uniquely offer dramatic environmental and economic benefits. These dyes meet the environmental and quality standards of the world’s best clothing brands while increasing yield and reducing processing costs for mills.


Industry challenges
The textile industry is a heavy user of natural resources such as water and energy. For many years, reducing this reliance has been a priority for textile producers, along with the related challenge of removing hazardous chemicals from the supply chain.

Many of the major textile-producing nations have strengthened their regulatory regimes to reflect greater awareness of resource scarcity and the environmental impact of industrial production. At the same time, the world’s brands and retailers are enforcing stricter standards to meet consumer demand for a cleaner and more transparent textile supply chain.

The situation is made more difficult since processing mills are also facing acute economic challenges. These include price volatility in cotton and other raw materials, as well as rising labor and energy costs.

Some mills have closed under the weight of these combined economic and environmental pressures. Others, however, are seeking new solutions. Taking a more long-term view, they want to improve productivity and profitability and meet more stringent environmental regulations and industry standards. AVITERA® SE is the answer.

 

Industry challenges


Major environmental impact
What does it take to produce one cotton t-shirt?

 

cotton tee

 


Innovative solution
AVITERA® SE dyes are poly-reactive dyes that ensure rapid and very high exhaustion for the world’s most widely used textile fibers: cotton and other cellulosic fibers and their blends. These new dyes significantly reduce water and energy consumption and carbon dioxide (CO2) emissions during the dyeing and washing-off process. They improve productivity, reduce costs and deliver the highest level of light- and wet-fastness across the entire shade gamut and color spectrum. More importantedly, they are free of para-chloro-aniline (PCA)* and other regulated chemicals.

“AVITERA® SE brings us a tremendous advantage,” says Mr. Heun-Tae Kim, President of Panko Vina Corporation, a major producer of knitwear for world markets.

“Since adopting AVITERA® SE, we use 50% less water. We also save a great deal of energy, since these dyes require a washing-off temperature of only 60°C compared to conventional washing off at 98°C. With improved right-first-time performance as well, this considerably reduces our manufacturing costs. AVITERA® also helps us satisfy our customers, who are very particular about product quality and very committed to removing all hazardous substnaces from the supply chain.”

Panko Vina has been using AVITERA® SE for three years. With the support of Huntsman Textile Effects, it is now going further to implement a Productivity Improvement Program that will optimize and standardize its processes and work practices to further improve yield and product quality.


Breakthrough innovation
Around 65% of the world’s annual production of about 30 million tons of cotton is dyed using reactive dyes. Huntsman developed these dyes in the 1950s as an alternative to direct dyes. The AVITERA® SE dyes are the first new reactive dye molecules to be invented for almost two decades. They also comprise several newly designed active reactive groups.

Using less salt than conventional reactive dyes, AVITERA® SE achieves a fixation rate of 93%. Since more of the dye is absorbed by the fabric, less than 7% remains unfixed in the dye bath effluent, as opposed to 40% of the mono-reactive dyes. The unfixed dye is also easier to remove at a lower washing-off temperature because it is not bound to the fabric fibers in a high-salt solution.

 

Fixation rate comparison

avitera technology
 

Economic sustainabillity
Processing mills can dramatically increase productivity with AVITERA® SE due to substantially shorter dyeing and washing-off cycles. Significant cost savings are also likely: recipe costs are comparable to today’s best available technology but processing costs are appreciably lower and reprocessing costs are minimal. Furthermore, the AVITERA® SE dyes can be used on diverse machinery and do not require mills to make a capital investment.

Significant economic benefits
• Higher productivity (25% or more improvement)
• Fixed cost savings and reduced effluent treatment costs
• Improved right-first-time production
• No capital investment

Improved annual performance
Mills that switch to AVITERA® SE dyes can expect significant savings and additional productivity.

productivity

Image shows the indicative annual savings and additional productivity for a 100 tons/day production plant when production switches to
AVITERA® SE dyes (assuming a balanced shade gamut of 20% pale, 30% medium, 30% dark, 20% extra dark shades)


Environmental sustainability
The AVITERA® SE dyes deliver water and energy savings of up 50%. They reduce CO2 by up to 50% and lower salt consumption by 20% as well.

They also comply with the Zero Discharge of Hazardous Chemicals (ZDHC) Group’s Manufacturing Restricted Substances List and the environmental requirements of leading brands and retailers. Fabrics dyed with AVITERA® are free from restricted arylamines, including para-chloro- aniline (PCA), at the current detection limit of 5ppm.

Mills that use AVITERA® SE dyes are thus able to meet the environmental standards of the world’s best clothing brands. This helps them maintain a positive image and boost the value of their brand while increasing yield, improving productivity and reducing processing costs.

Significant environmental benefits
• Reduce water, energy, CO2 emissions and salt
• Produce PCA-free* fabrics
• Increase compliance with legislation and RSLs
• Improve brand image and reputation

Performance improvements compared to Conventional Dyes
Conventional methods of dyeing 1 kg of cotton use up to 100 liters of water, the equivalent of one bathtub. AVITERA® SE dyes go even further to reduce substantially less water and energy than conventional hot or warm dyeing systems.

Graphic to be added here (this is a screen grab only):
 
* Dyeing 1 kg of cotton with AVITERA® SE, compared to BAT


Ongoing commitment from the innovation leader
“Huntsman Textile Effects introduced AVITERA® SE to help the industry address its most pressing economic and environmental sustainability challenges. We continue to develop this technology to help textile mills and brands achieve cost-effective production, improved textile products and minimal environmental impact,” says Paul Hulme, Global President, Huntsman Textile Effects.

 

 

* Current detection limit 5ppm