Reducing emissions by improving energy consumption is essential but improving the consumption of resources is also key to becoming a greener organization. Therefore, we have implemented several policies and technology to reduceour raw material usage and recycle our production waste.
1- Our fabric cut/ garment ship ratio is currently 97% due to second degree garments and rejected fabric at panel inspection stage. We aim to improve this figure to 99% through serval implementations of quality and planning procedures.
Through a 2% improvement in our cut-ship ratio we will save approximately1.8% of our annual fabric consumption. This translates to 150,000 KG of fabric per year and subsequently 105,000 m3 of natural gas saved only within our own operations!
2- We invested and implemented Gerber’s latest marker marking technology AccuNest which uses AI technology to improve marker efficiency. The program is expected to improve our markers efficiency by 1% across our total production. This will save us approximately 83,000 KG of fabric and 58,000 m3 of natural gas per year.
3- All our cutting room fabric wastage is recycled through sale contracts with home textile manufacturers that clear our wastage on a weekly basis. The fabric fibers are used to manufacture new end-products that are sold in the local market.
1- Our process improvement actions in our finishing department lead to an increase in pick-up rate of wet fabric from 4% to 15%. By changing our stenter treatment from dry-to-wet to wet-to-wet process we managed to decrease the concentration of Silicon applied to the fabric by 10%.
2- We are constantly innovating our dyeing procedure and looking for techniques and chemical solutions that will achieve better quality results with lower chemical consumption. We changed our wash off and oil removal chemical choice to a 2-in-1 solution provided by an alternative supplier. The new solution is also effective at a neutral PH as opposed to the old chemicals used that only operated in alkali conditions. Therefore, we also managed to save 0.5g/l of Acetic Acid and Soda Ash in each production batch.
3- Our choices of dye stuff use are not judged on quality and economical metrics only, but we also consider the concentration of dye stuff required to reach the requested color. We use higher quality more expensive dye stuff that will achieve the same color shade with a lower concentration.
4- The termination of the high liquor ratio dyeing jets lead to a reduction in consumption of dye stuff and chemicals. Our investments also include a new set of Air-Flow technology jets that operate at a liquor ratio of 1:3.