1. Green SolutionsMineral Technology in Textile Processing andWater Saving Program

2. HistoryTANATEX Chemicals strongly believes in the use of minerals intextile processing. Over the years we have successfully launchedproducts like:TANNEX GEO Multi-functional product for pretreatment,dyeing and correction of faulty finishingTANNEX NOVECO Multi-functional product forpretreatment, dyeing and correction of faulty finishingTANATERGE ELB Nano-clay based composite for the pre-treatment of elastane blendsTANASPERSE MDA Mineral desizing agent for PA & PESTANATERGE M-RE Mineral soaping agentTANNEX RENA liquid 01 Ecological stabilizer for hydrogenperoxide of an extraordinary quality Green Solutions. Slide 3. TANNEX NOVECO Multi-functional product for pretreatment, dyeing and correction of faulty finishing 4. TANNEX NOVECOClay-based multi-functional agents Clay is a so-called layeredaluminosilicate of extremelysmall particle size In water these particles arehydrated and they possess anegative charge. There are many clay types,depending on their chemicalstructure and deposit area e.g. Kaolinite, Vermikulite,Smektite, Illite The clay used in TANNEXNOVECO has largest surface ofapprox. 800 m/g Green Solutions. Slide 5. TANNEX NOVECOScheme of a clay particle The negatively chargedparticles have a largepotential adsorption surfacefor:(-) (-) (-) hydrophilic materials and (-)(-)(-) polymers 1 nm hydrophobic waxes and oils metal ions 200-10.000 nm Excellent stabilising effectfor H2O2 Very good lubrication toprevent crease marks Green Solutions. Slide 6. TANNEX NOVECO Absorption of impurities/dirtAbsorption of clay on oilFat and impuritiesClay sheetsGreen Solutions. Slide 7. TANNEX NOVECO The Stabilizer ConceptTraditional Organic Stabilizer TANNEX NOVECOGreen Solutions. Slide 8. TANNEX NOVECOSpecial Application Stripping fluorcarbon & silicone finishes1 ml/l DIADAVIN HLS Conc. 013 5 ml/l TANNEX NOVECO3 5 ml/l Caustic Soda 50 % repair at 90 100 C during 40 50 minutes rinse thoroughly with warm & coldwater repair the dyeing (if required) andapply finish again Green Solutions. Slide 9. TANNEX NOVECO Special ApplicationPrevent the deposit of oil andAs an lubricant in dyebath oligomer on machine Due to its absorption TANNEX NOVECP shows properties the machines are excellent lubricant kept perfectly clean. Someproperties on all cellulose polyester dyers use based fabrics and knits, e.g. Cotton, Viscose, Modal, 0,5 ml/l TANNEX NOVECOPolynosic and especially Lyocell fibres and give them To avoid soil and dyestuff a nice soft handle deposits in their machines Also on synthetics good To remove the knitting oil results are being obtained from the fabric. Cleaning operations can drastically be reducedGreen Solutions. Slide 10. Modern requirementsTANNEX NOVECO is GOTS approved.TANNEX NOVECO can be used for all textiles applying for theko-Tex Standard 100.TANNEX NOVECO can be used for textiles applying for theEKO labeling requirements. Green Solutions. Slide 11. TANNEX NOVECOPhysical and ecological data- Aspect: Light brown- Viscosity : 800 mPas *- Ionicity: Nonionic- pH: 8.0 9.0- Density : 1.1 g/cm3- Fish toxicity : LC50 > 100 mg/l- Biological elimination : > 70%(Zahn Wellens - OECD 302B)- MBAS value:0 mg/g- BiAS value: 110 mg/g- COD value : 369 mg/g- BOD5 value: 20 mg/g* See additional info on rheologyGreen Solutions. Slide 12. TANNEX NOVECOEnvironmental awareness TANNEX NOVECO is the answer for environmentally responsible textile processing. TANNEX NOVECO is harmless for the aquatic environment, shows a high biological elimination (>70%) and is therefore not dangerous for all in water living species.TANNEX NOVECO is our next step in sustainable textile processing. Green Solutions. Slide 13. TANNEX NOVECOPositive effect on COD and BOD5Some practical measurements in a textile factory, which clearlyshowed the decrease of COD and BOD figures.Average reduction of COD values: 25%Average reduction of BOD values: 53%The organic substances, as soluble or dispersed substances, areabsorbed by the clay of TANNEX NOVECO and thus removed fromthe water. Of course biodegradation will continue on the clay.But the cost for discharging this effluent water into communaleffluent streams will be reduced drastically.TANNEX NOVECO helps you to respond to environmentalissues in a simple way Green Solutions. Slide 14. Practical Run - Example 1Fabric :Interlock Co.,100%Machine: FONGS ECO-3-D2T L.R.=1:7 Factory s recipe TANNEX s recipe TANNEX s recipe Scouring agent:C- SCO (o.w.f): 1.0%, Stabilizing agent:TANNEX NOVECO:TANNEX NOVECO: ST201(o.w.f.):0.5% , Dyebath lubricant, 1.0%(o.w.f.), 1.5%(o.w.f.), FIRCHEM SF-290T: 0.7%,COD value / Residual liquid after bleaching (dont include acid rinse and Bio-polishing enzyme rinse)/ppm 67505620 4480COD reducing rate16.7%33.6% Green Solutions. Slide 15. Reduction of COD80% of the BOD and COD values are originated from thechemicals/waste in the pretreatment process.Table below shows the comparison of COD of different pretreatmentconditions:80007000600050004000Ser i es1300020001000 0 pr evi ous TAN EX NTAN EX N N VEC : 1%O O N VEC : 1. 5% O O Green Solutions. Slide 16. Practical Run Example 2Comparison of COD values of pretreatment and opticalbrightening in one bath with TANNEX Noveco vs. existing recipe.COD is reduced by 17%120001000080006000 Ser i es140002000 0pr evi ous TANNEX NOVECOGreen Solutions. Slide 17. TANNEX NOVECOApplication recommendationsAgain very positive effects have seen when wetting out thematerial with TANNEX NOVECO, before adding peroxide andcaustic. This also has a very positive effect on the possible foam levels.Adding peroxide before the caustic strongly improves the bleachbath stability, final whiteness and final Dp values.Prefered chemical addition: 1) Water 2) TANNEX NOVECO, wet out the material for several minutes 3) Peroxide, run for 5 minutes to exhaust on TANNEXNOVECO 4) Caustic, raise temperature for bleaching Green Solutions. Slide 18. TANNEX NOVECO Application recommendationsFull white bleachingWhite for dyeingLiquor ratio 10:1 Liquor ratio 10:130 45 min. @ 95 - 110C 30 45 min. @ 95 - 110C12 ml/l TANNEX NOVECO 0.8 1.5 ml/l TANNEX NOVECO2 3.5g/l NaOH 100%1.5 3g/l NaOH 100%6 10 ml/l H2O2 35%25 ml/l H2O2 35% 0.7% BLANKOPHOR CO liquid Very good stabilisation Good whiteness for dyeing Excellent whiteness Very good cleaning andscouring effect High Dp value Good rewetting effect Excellent absorbency Excellent lubrification and Soft handle and bulky handlecrease mark preventionGreen Solutions. Slide 19. The effect of adding sequence Fabric: 100% cotton knit Traditional sequence: adding caustic first then adding peroxide Recommended sequence: adding peroxide first then adding caustic The fabric strength usually will lose after bleaching especially for high counts yarns. Adopt the recommended sequence can reduce the loss of fabric strength. Fabrics original bursting strength: 418.10 NTrad. seq. Noveco seq.Whiteness (CIE)69.4670.57 Burst Strength367.55 N 389.05 N Loss rate in burst12.09% 6.95% strengthGreen Solutions. Slide 20. TANNEX NOVECO Foam levels Foam level at 20C Foam level at 80CTANNEX NOVECOTANNEX NOVECO Directly After 1 min DirectlyAfter 1 minGreen Solutions. Slide 21. TANNEX NOVECO Silicone emulsifyingTANNEX NOVECO contains specialsurfactants giving the absolute cleaningeffect, improving the hydrophility afterbleaching, but also showing fantasticsilicone emulsifying properties.TANNEX NOVECO is the multi-purpose product for all Co and Co blends inbleaching and pre-scouring.Green Solutions. Slide 22. TANNEX NOVECO Silicone emulsifying (1 hour) BLANK TANNEX NOVECO (After 1 hour)(After 1 hour)Green Solutions. Slide 23. TANNEX RENA liquid 01Ecological stabilizer for hydrogen peroxide of anextraordinary quality 24. TANNEX RENA LIQUID 01 Based on a new sodiumEcological stabilizer for silicate, which does perform hydrogen peroxide of an in a different way compared to classical waterglass (noextraordinary quality polymer structures) No residues on fabric, cleaner machines Soft handle of the goods Outstanding dyeing and printing propertiesGreen Solutions. Slide 25. TANNEX RENA LIQUID 01 Buffer capacity & Optimum pHGreen Solutions. Slide 26. TANNEX RENA LIQUID 01 Solubility and temperature, influence of hard waterGreen Solutions. Slide 27. TANATERGE M-REMineral Soaping Agent 28. TANATERGE M-REMineral soaping off agent for REactive dyestuffs Special soaping off agent forreactive dyestuffs based onminerals. The best and the most ecologicalElectron-microscopical pictureway to soap off hydrolyzed reactivedyestuffs.Mineral based, thus very low COD and BOD valuesVery good removal of hydrolyzed reactive dyestuffsApplicable in discontinuous and continuous processingCan be applied for post-washing of reactive printed goodsHydrolyzed dyes are prevented from re-striking onto the goodsNon-foaming Green Solutions. Slide 29. TANATERGE M-RE Mineral soaping off agent for REactive dyestuffsGreen Solutions. Slide 30. TNANTERGE ELBNano-Clay based composite for pre-treatment ofElastane blends 31. Foaming Property of TANATERGE ELB1 unit = 0.5 cm foam TANATERGE Jet - Simulator ELB Unit Is a non foaming 10 detergent, what can9 be used on all8 machines where foam7 might be a problem6543210 20 30 40 5060 7080 90 98 C 1,85 g/l TANATERGE ELB 0,93 g/l DIADAVIN DSPGreen Solutions. Slide 32. TANATERGE ELB Nano-Clay based composite for the pre-treatment of Elastane blendsGreen Solutions. Slide 33. Discontinuous Application Ratio 10:1 Polyester (micro)/Elastan or Polyamid/Elastan 120 Discontinuous application 100Temperature [C]806050C 1540min Dyeing20 drain 0 0 10 2030 4050 60 70 80Time [min] Fill the machine and add TANATERGE ELB 1 2 ml/l Refill and add Soda ash 0,5- 1 g/lTANATERGE ELB 0,5 ml/lother dyeing auxiliariesdyestuffsGreen Solutions. Slide 34. Discontinuous ProcessExample for prebleaching Knitwear, CO/ Elastan Preparation for light and mediumRatio 10:1 shades10095 C 25 80Hot overflow rinse !!! Temperature [C] 60 NaOH 38Be 2,0 ml/l25-40C 10-15 min 40Hydrogenperoxid 50% 3,0 ml/l drain 20 TANATERGE ELB refill 0,5 ml/l0010 20304050Reactive dyeing Time [min]pH 6-in the same bath 7 TANATERGE ELB 1,5 TANAZYM PK 0,15-0,25 ml/lml/lPrevention of formation creases: heat up slowly, use TANATERGE ELBGreen Solutions. Slide 35. Discontinuous ProcessExample: bleach with opticalbrightener Co/Elastan liquor ratio 1:10 95-100 C 30-60 10080 PLEXENE QXL 1 ml/ltemperature C NaOH 50 B4-6 ml/l 70C602 C/min.H2O2 50% 6-8 ml/l rinse overflow BLANKOPHOR BA fl. 0,7 %40 (add slow) TANAZYM PK20 (Peroxide killer TANATERGE ELB 1-3 ml/lacidify/softener 0 020 4060 80 100time [min] Prevention of formation creases: heat up slowly, use TANATERGE ELBGreen Solutions. Slide 36. Water Savings ProgramsSome practical examples 37. Water savings programs Water shortage is an emerging word in textile processing industry So everybody wants to save water in their process A complete new way of thinking is necessary TANATEX can and will play its part in thisnew challenge This presentations will give you someideas and some practical experiences Green Solutions. Slide 38. Water consumption in average textile company Total average water consumption per kg textile will be around 45 l/kg, however specific cases are known where up to 100 l/kg will be used. (Information present customer: - 80.000 m production per day @ 400 g/m (32.000 kg)- Total effluent per day 1.500 m3/day (1.500.000 liter)- Total water consumption per day 47 l/kg (1.500.000 liter / 32.000 kg) Average water consumption in the pretreatment only, will already be around 15 20 l/kg. Green Solutions. Slide 39. How does WATER fit in our philosophy ?We promote WATER from different points of view:- less total waste water and less effluent load- cost savings in water and energy- cleaner water by less chemical waste in effluent- specific biological treatments but most important:WE BELIEVE IN WATER ! Green Solutions. Slide 40. Example 1Continuous bleachGreen Solutions. Slide 41. Less total waste waterEffect of TANNEX RENA liquid 01 Using TANNEX RENA liquid 01 makes it possible to reduce the amount of NaOH to max. 40% of the amounts use for classical organic stabilisers. This could easily result in a water reduction of 2 3 l/kg per application (cold pad batch and/or pad steam). Consuming less water directly reduces the energy consumption and therefore strongly reducing costs per kg. Green Solutions. Slide 42. Objective of industrial trials in this example Optimize washing procedures and reduce total water consumption. Create a single procedure (desizing and bleaching) for all processes (blanquear and descrudar) in order to replace the two different procedures as for actual standard procedures. Replace actual alkaline boil off by an enzymatic desizing. Increase productivity by simplifying procedures and reducing changing times for different procedures. Create a green and sustainable process based on GOTS approved products, low harsh chemicals (NaOH and H2O2) and reduction of water and energy. Green Solutions. Slide 43. How to achieve these objectives ? First pad steam treatment based on enzymatic desizing and strong hardness and heavy metal complexing. Without the use of NaOH in this first pad steam treatment water consumption can be reduced. Reduce the amount of alkali in the second pad steam bleach so that also there water can be reduced. Low alkali bleaching treatments are safer for the material, especially for the Elastane fibres. Lower amounts of caustic and peroxide in combination with a good clean up of the material using complexing agents gives less fibre damage, higher Dp values and tearstrengths. Green Solutions. Slide 44. Standard customer process: Alkaline boil off and BleachingBlanquear 100% Co and Co/EL (Cama) 3 ml/kg StabilizerNo 6 ml/kg Scouring agent neutralisation 18 - 25 ml/kg NaOH 48 Be 40 - 50 ml/kg H2O2 35% 3,5 l/kg water2 ml/l Stabilizer3,5 l/kg water6 ml/l Scouring agent20 ml/l NaOH 48 Be15 ml/l H2O2 35% 7 9 @ 99C2,5 l/kg waterAlkaline boil-off3 @ 99C 95C 95C 95C 95C 20C80C Impregnation XX 60C @ 20CTotal consumption 9,5 l/kg waterAlkaline boil offBleaching Green Solutions. Slide 45. TANATEX process: Enzymatic desizing and Bleaching Blanquear 100% Co and Co/EL (Cama)8 ml/kg TANNEX RENA liquid 01No2,5 ml/kg TANATERGE ADVANCE neutralisation12 15 ml/kg NaOH 48 Be35 40 ml/kg H2O2 35%2,5 l/kg water2,0 l/kg water 8 ml/l TANAZYM LTC 01 6 ml/l PLEXENE PREP7 9 @ 99C 1,0 l/kg water 3 @ 99C95C 95C 95C 95C20C80C ImpregnationXX 60C @ 20C Total consumption 5,5 l/kg waterEnzymatic desizing to replace Alkaline boil offBleachingGreen Solutions. Slide 46. Standard production 100% Co and Co/EL (Tight strand or Roller bed)1st pad steam bleaching Pad steam bleaching- Impregnate at 20C- Impregnate at 20C- Wet pick up 70% - Flex Nip impregnation (100%)- Steam for 3 minutes at 100C- Steam for 4 - 9 minutes at 100C 2 ml/l stabilizer3 ml/kg stabilizer 6 ml/l scouring agent6 ml/kg scouring agent20 ml/l NaOH 48B18 25 ml/kg NaOH 48B15 ml/l H2O2 35%40 50 ml/kg H2O2 35%- Wash off in 1 unit at 95C using- Wash off in 6 units at 95C using 3,5 l/kg water. 3,5 l/kg water and 2,5 l/kg in unit 7.Green Solutions. Slide 47. Blanquear 100% Co and Co/EL (Tight strand or Roller bed)Pad steam desizingPad steam bleaching- Impregnate at 20C- Impregnate at 20C- Wet pick up 70% - Flex Nip impregnation (100%)- Steam for 3 minutes at 100C- Steam for 4 - 9 minutes at 100C 8 ml/l TANAZYM LTC 018 ml/kg TANNEX RENA liquid 01 6 ml/l PLEXENE PREP2,5 ml/kg TANATERGE ADVANCE12 15 ml/kg NaOH 48B- Wash off in 1 unit at 95C using35 40 ml/kg H2O2 35% 2,5 l/kg water.- Wash off in 6 units at 95C using2,0 l/kg water and 1,0 l/kg in unit 7.Green Solutions. Slide 48. Standard waterconsumption 100% Co + Co/EL Standard production: - After 1st PS treatment : 3,5 l/kg (unit 1) - After 2nd PS treatment : 3,5 l/kg (unit 5): 2,5 l/kg (unit 6) Total waterconsumption : 9,5 l/kg Consumption (1st and 2nd PS bleach) : NaOH H2O2 - in 1st PS treatment: 2015ml/kg - in 2nd PS treatment: 2550ml/kg Total consumption4565ml/kg Green Solutions. Slide 49. Tanatex waterconsumption 100% Co + Co/EL Production trials: - After 1st PS treatment : 2,5 l/kg (unit 1) - After 2nd PS treatment : 2,0 l/kg (unit 5): 1,0 l/kg (unit 6) Total waterconsumption : 5,5 l/kg Water savings: 4,0 l/kg ~ 40% reduction Consumption (1st and 2nd PS bleach) : NaOH H2O2 - in 1st PS treatment: - - ml/kg - in 2nd PS treatment: 1540ml/kg Total consumption1540ml/kg Base-chemical savings60 %~ 40% Green Solutions. Slide 50. Cost savings water and energy Based on process optimations saving 4,0 l/kg water (40% reduction), using less NaOH in the total process, using for all procedures the combination of enzymatic desizing and pad steam bleaching it proved possible to save, within the total process (water, chemicals and energy): ~ 100.000 Information customer: - 400.000 m production per week @ 400 g/m : 160.000 kg - Annual production (@ 42 weeks/year) : 6.720.000 kg - Standard water consumption:63.840 m3/year - Water savings TANATEX system: - 26.889 m3/year Green Solutions. Slide 51. Conclusions Whiteness similar (Co and Co/EL) or better (Linos) than the standards using less peroxide (~10 - 40% reduction). Lower damage to the fibre (confirmed in lab. controls) Hydrophility and desizing upto the standards. Single pretreatment procedure, no changes between bleaching and boiling off. Strong reduction of caustic in bleaching. Strong reduction of water in washing off (~40% savings). Total cost savings upto 100.000 for the complete process Green Solutions. Slide 52. Example 2BioScouringEnvironmentally friendlypreparation of cellulosicGreen Solutions. Slide 53. BioScouring BioScouring BioScouring is an enzyme based process in which a modified PECTINASE is used to remove pectine and natural waxes from the fibers. BioScouring could replace all alkaline boiling procedures. BioScouring is mild process in which the primary cell wall of thefibre is being prepared for dyeing and/or bleaching. No caustic required for the saponification of natural impurities. Green Solutions. Slide 54. BioScouringEffect of BioScouring Less aggressive attack of the fiber. Less weight loss by only preparing the pectine part. Smooth surface of fiber. No residual caustic in the fiber. After alkaline boil off No neutralization required. Softer handle of the fiber. Improved look/aspect of thefiber. Permanent appearance ofAfter BioScouringthe fiber. Green Solutions. Slide 55. Deformation of cellulosic fibers BioScouring Alkaline boil offGreen Solutions. Slide 56. Proces shortening examplePreparation for dyeingStandardprocedure: Totalwaterconsumption11l/kg CPB rinse Caustifirinse Neutralizebleach 3 l/kg cation 8 l/kgBioScouringproces: Totalwaterconsumption5l/kg Bio rinse Scouring5 l/kg Watersavings6l/kg Green Solutions. Slide 57. Cost savings water and energyWater: Water savings: 6 l/kgEnergy: Water to be heated : 6 l/kg Energy savings (T 50C) : 0,3498 kWhTotal water saving : 142.000 l/day = 57.600.000 l/year = 7.600 m3/yearTotal energy saving : 11.194 kWh/day = 3.358.080 kWh/year Green Solutions. Slide 58. LOGIC DyeingOne-bath isothermal scouring and dyeing of cotton knit goods and their blends,with reactive dyesLOGIC DYEING: Less water and energy One-bath Greige dyeing Isothermal Cellulosics Green Solutions. Slide 59. LOGIC DyeingLOGIC DYEING is an innovative concept to processcotton knit goods and their blends.A time saving one-bath isothermal scouring & dyeingprocedure enabling higher efficiency, cost reductionand a careful use of energy.Because we care Green Solutions. Slide 60. Benefits obtained with LOGIC Dyeing Short and simple process Time saving Higher production capacity Less energy consumption Higher profitability Less fiber degradation Higher dyes penetration Higher shade reproducibility More ecologicalGreen Solutions. Slide 61. LOGIC Dyeing process with reactive dyesDYEALKAFLOSalt atthe start SALT20-30 min60 min portions /5 5 5 linear dosing progressive dosing*20-30 minTANALEV K-DC 01PLEXENE CA * 60CPERSOFTAL LpH 6-7LEVEGAL RL where neededGreen Solutions. Slide 62. Technical features of TANALEV K-DC 01TANALEV K-DC 01: One of the main characteristics to be highlighted is that it remains active during the whole process with its wetting, detergent, emulsifying and dispersing actions. Its effectiveness is maintained in the whole temperature range even with large amounts of electrolytes. This differs from conventional nonionic products whose turbidity level decreases together with their best characteristics.(1) TANALEV K-DC 01 (2 & 3) Conventional nonionics Due to its anionic characteristics it does not affect the dyeing agents during the dyeing process. Low foam level compared with other alternative anionic products. Pronouncing Right-First-Time processing.Green Solutions. Slide 63. LOGIC Dyeing: savings Where are the savings in the LOGIC dyeing system? We leave out the complete pretreatment(scouring or alkaline boil-off or pre-bleach)Shorter ! This saves mostly 2 baths, with theaccompanying water, energy andtime reduction Green Solutions. Slide 64. But.. Can we approach this only technically ???? The answer is no. We have to approach the customer differently. Green Solutions. Slide 65. Important !! The customer needs to be willing to consider his total process costs and not only auxiliariesGreen Solutions. Slide 66. Because we care