Karl Mayer launched Greendye, an innovative technology for producing denim fabrics with minimised ecological footprint at ITMA 2019

This nitrogen-based technology ensures less environmental impact and more efficiency during indigo dyeing. With its high concentration in the dye bath and under nitrogen atmosphere, the dye diffuses and migrates more intensely into the fibre than in case of conventional comparable procedures. The yarn can absorb three times more dye in a dye vat. In this way, it is possible to reduce the number and length of vats, with positive effects for the environment. The chemical consumption can be reduced considerably, a minus of 50 per cent is possible when using hydrosulphite and caustic soda, and there is also less yarn waste. Moreover, due to the good fixation of the dyestuff on the fibre, considerably less water is required during the washing process.

Karl Mayer took over the patents for the innovative indigo dyeing technology from Master in 2018. The company then carried out extensive work for the further development and fine tuning of this technology. One of the milestones in this development was the operation of a pilot machine at the Denim Competence Center in Mezzolombardo, Italy, at the beginning of this year. The dyeing system maps the industrial production process at a scale of 1:10 and it has already supplied the first warp beams.