Karl Mayer Rotal, the site with the Karl Mayer Group's denim center of excellence, has sold its first Greendye machine to Taiwanese manufacturer Nein Hsing

The machine ensures two times cleaner and three times more efficient indigo dyeing than with the processes of conventional equipment. It uses the nitrogen (NOX) technology to control the chemical dyeing process. The nitrogen atmosphere in the technology temporarily prevents the necessary oxidation of the indigo dye. Further advantages result from the design of the dyeing vats. A high-flow, low-speed indigo circulation system and a design that avoids turbulence and surface foaming significantly reduce chemical consumption. A saving of up to 50 per cent of hydrosulphite and caustic soda – the main environmental polluters of the process - and thus a halving of the gray water footprint is possible.

A reduction of 50 per cent is also possible in the final washing water consumption. Thanks to the NOX reactor, the Greendye system requires only three dyeing baths instead of nine - like conventional systems - to achieve the same indigo dye shade, with correspondingly lower water consumption. In addition, the washing process is more economical due to the higher fixation of the indigo dye on the fiber.

Fewer dyeing baths also mean shorter dyeing sections. The reduction of daily water and chemical consumption as well as waste water and yarn waste optimizes not only the environmental balance but also the production cost in indigo dyeing. In addition, the operating costs are extremely low. Compared to traditional indigo dyeing systems, the Greendye system requires less space due to its shorter design, less maintenance, less time for operation and less spare parts for the same output.