Increasing consumer demands for sustainable processes is heightening the pressure for textile companies to be environmentally friendly. In a troubled financial climate, laundries have had to look far for affordable solutions, but now they need not look any further for an answer to their concerns. Novozymes has recently established a new application that enables textiles to be bioblasted and dyed simultaneously in the dyeing bath. Cellusoft CR is the solution that gives laundries the winning hand and makes competitors work hard to match its results.
Working flexibility at no added cost
Cellusoft CR is a robust neutral bioblasting cellulase that prevents pilling and increases the smoothness and softness of fabrics. The enzyme works at a broad pH range of 5–8 which means that it can reduce the need for harsh chemicals or an acidic solution in the bioblasting process.
The enzyme was originally launched to replace traditional acid cellulases. With its flexible working conditions, scientists at Novozymes’ laboratory explored the applicability of Cellusoft CR to processes pertaining to textile laundries – and with great success. “Because there’s no residual peroxide before the dyeing in laundries, it’s not necessary to use a product that has the ability to remove residual peroxide and bioblast – like the patented Cellusoft Combi does. The enzyme Cellusoft CR has a broad pH range and is stable with dyeing auxiliaries, which makes it ideally suited for combined dyeing and bioblasting in laundries,” explains Len Tai Ng, Formulation Chemist at Novozymes.
So while traditionally, laundries bioblast in a separate process before or after dyeing, Cellusoft CR can be applied simultaneously at any stage of the process prior to alkali addition for reactive dyes. It is a flexible approach that decreases time spent on textile processing by eliminating an entire processing step. Considering how many processes a laundry runs per day, this can save a lot of time.
And let us not forget that time is money: Cutting down on production time decreases labor costs and consumption, and leaves room for creating additional batches, thus increasing output. For laundries that means fast and efficient fashion creation! “Cellusoft CR in dyeing has allowed us to increase our throughput by 25%, and as a bonus on top of that we’re now producing garments with an increased level of quality,” says Mr. Xie, Production Director of Novozymes’ customer, the Co-prosperity laundry in China.
FIG. 1. TIME SAVINGS WITH DIFFERENT DYES
Novozymes Cellusoft® CR saves production time in combination with different dyes
Get softer, smoother, and more radiant fabrics
The “CR” in Cellusoft CR stands for “Color Retention” because the enzyme has proven to ensure greater color retention compared to typical bioblasting with an acid cellulase. In addition to conventional use of Cellusoft CR it can now also be used in combined dyeing and bioblasting as it is compatible with most dyes that laundries use to obtain different colors, shades, and fashion looks, for instance a worn look for pants. “Because Cellusoft CR has features that allow it to withstand harsh chemicals, the solution functions optimally in a combined bath with many types of dyes. It’s definitely also worth considering that, in some cases, the combined approach can cut down processing time by up to 47%. That’s almost half of the average standard processing time, which could mean a substantial optimization of processes for many laundries,” explains Han Kuilderd, Customer Solutions Manager at Novozymes.
FIG. 2. COMPARISON OF TOTL PROCESSING COST
Novozymes Cellusoft® CR is the sustainable alternative that decreases the usage of and costs associated with steam, electricity, water, and labor as well as the need for acidic applications. Case: China.
Fabrics are often prone to pilling and fuzz after wash and wear by the consumer. Cellusoft CR significantly reduces the risk of this happening by reducing the risk of pill formation on the fabric. “Cellusoft CR leaves the garment smoother, softer, and nicer to wear. So it’s not only a cost and time advantage to bioblast garments in the dye bath for laundries, it’s indeed also an added value for the end user and ultimately the producer,” says Han Kuilderd.
Another interesting benefit of Cellusoft CR is that it minimizes the risk of friction. Normally, thin or light fabric is often prone to being torn at the seam lines during washing due to mechanical action and fabric friction, but because this process is combined and shorter, Cellusoft CR leaves the fabric much stronger.
Go the enzymatic way
The combined approach to dyeing and bioblasting garments can in some cases reduce water usage by up to 70% per batch. “There lies a greatpotential in solutions like these that can combine processes. Imagine a textile laundry industry that exclusively uses this approach for bioblasting garments – that can amount to a lot of additional water in a world where clean drinking water is becoming scarcer,” says Han Kuilderd and continues: “Now the focus for Novozymes is on getting good traction with some of the key players in this tough and fragmented industry to showcase what we’re capable of. We can really make a difference, so I’m very optimistic about that,” he concludes.