While the general cotton manufacturing still involves the some of the same processing methods that have been used for years—such as dyeing, printing and finishing —cotton production companies have decreased water use, energy and have implemented green processing methods. Such green efforts include companies building clean water reservoirs and reducing chemical use, strategies that have proven to be environmentally efficient.
Safer Processing Techniques
In the past, cotton producers would process their material with chemicals for pest control and to remove specific impurities from the plant. Now, various companies are implementing proteins in place of the harsh chemicals, achieving similar but safer results. Researchers have developed industrial enzymes, such as novazyme, which are used to treat the cotton and effectively cut down on chemicals at the same time. Modern electronic technology also allows workers to monitor cotton via computer systems, reducing expended machinery power and work time.
Dyeing and Digital Printing
One reason that cotton is such a coveted material is its color retention capability. There are variations of dyeing, which generally involves processing the cotton through a series of rollers that press the dye solution onto the material. According to Cotton Incorporated, conventional technology uses water to transport the fabric through machines during dyeing and printing; however, some manufacturing plants use newer processing technology involving air, which cuts down on waste water.
Conventional methods of printing vary and often involve mesh screens and roller printing. As a reflection of such technologically innovative times, more companies are employing digital printing. Developers have formulated new inks that are compatible with digital printers, implementing a processing method which cuts down on dye and processing wastes. Additionally, companies are constructing and using their own canals and structures as water treatment systems, a green effort that may become more widespread in the future.
The Finishing Process and Modern Treatment
Typically, the finishing process is the final step of the cotton production cycle, and processing treatments depend on the desired aesthetic and feel of the product. Additionally, a piece of cotton product may be processed with multiple finishes. Such finishes include treatments that produce specific qualities, such as flame retardant material, or a sheen appearance. Polished cotton processing, for instance, involves the chemical treatment of satin or plain weaved cotton to achieve varying degrees of a shine. While these standard methods of finishing involve water and chemical treatment, some plants have implemented the use of foam. Applying foam to cotton fabric at a reduced rate results in less water and waste.