Indigo Mill Designs (IMD) has developed a disruptive, foam dyeing process for producing denim. Foam dyeing of yarn is a new technology that is environmentally friendly and cost effective. However, it couldn’t be put to much use in denim manufacturing because the indigo dye used to create the blue color reacts to oxygen in the air.
IMD’s Indigo Zero solution overcomes this limitation, resulting in net reduction of water and energy use of more than 90 per cent. In addition, the foam dyeing process reduces chemical use while achieving the same or better dye quality compared to conventional processes.
A large fabric mill uses millions of gallons of water every day to dye denim. IMD’s innovation can greatly reduce that amount and cut the energy needed for dyeing and wastewater treatment.
IMD’s foam dyeing process will allow fabric mills to produce much smaller quantities than conventional dyeing processes, when desired. In addition to reducing waste, smaller fabric runs will allow for exciting design and marketing innovations in the denim industry. Wrangler is among the investors in this process. Wrangler has advanced the commercialization of this technology since it has the potential to dramatically improve the environmental impact of the industry and help the brand reach its goals for water conservation.