“Sustainability is not just a slogan for us, it’s an ethos and a way of life.”
We are a business with a purpose. Since the time we were established in 1995, Crescent Bahuman Limited has had sustainability and responsible manufacturing at its operational core. We are not like any another denim manufacturing company—our uniqueness lies in the way we have built our vertically integrated facility, which we call our “ecosystem,” and how we give back to our people and the planet.
The cornerstone of our business strategy is to provide the most sustainable solutions to our customers while maintaining a balance as the greenest ecosystem the denim industry has known.
As a pioneer vertically integrated denim mill, we are aligned with the UN Sustainable Development Goals and guided by an approach of “responsible consumption and production” and “partnership for goals.”
A concrete part of our strategy is our approach towards the measurement of consumption and production of raw materials, fibers and especially our dyeing processes. This has pushed us to bring efficiency and transparency into our value chain systems.
Speaking of transparency, we have been able to measure the impact of processes and inputs at each stage of our process. Using the “Environmental Impact Measuring” software from Jeanologia, we are able to quantify the success of our own sustainability initiatives. This builds on the trust placed in us by our reputed customers as we further strive toward mutual sustainability goals.
Developing denim through sustainable raw materials
We use sustainable raw materials in the majority of our fabric productions. For example, we have recently established a state-of-the-art, in-house post-consumer waste (PCW) recycling unit. We recycle almost 210 tons of PCW and 236 tons of post-industrial waste (PIW) on an annual basis, thus meeting Global Recycled Standards (GRS). Our goal is to make 80 percent of our fabric with recycled materials by the end of 2023.
Additionally, we use regenerated materials from traceable sources, choosing fibers originating from business partners with the most sustainable business practices. We have mastered the optimal use of recycled plastic bottle waste for fibers, which we source from Repreve™.
Hemp is a sustainable alternative to cotton for CBL because of its antimicrobial qualities. Requiring significantly less water to grow, hemp’s extra strength and absorbency provide ultra-comfortable and abrasion-resistant solutions. We are currently looking at adding hemp to our product line, and have educated and created awareness in collaboration with the Pakistani government to create pro-hemp farming legislation.
To minimize our environmental footprint, we are reducing consumption of virgin cotton. We are transforming our production by using alternative and recycled materials as well as maximizing organic and BCI cotton usage.
We are proudly a Cradle to Cradle (C2C) Certified™ company and are on track to shift almost 15 percent of our fabrics produced to C2C standards.
How CBL saves water and chemicals in the dyeing process
The most critical process throughout our denim manufacturing practice is fabric dyeing, as this is where we can conserve precious natural resources like water and chemicals. By partnering with leading research-based institutions, we have developed precision-based technologies in our dyeing processes.
For example, our Naya Denim indigo-dyeing process is designed to be precision personified, saving nearly 99.5 percent of water at the dyeing stage, and another 80 percent of water in finishing. The process has been audited and validated by quality assurance service TUV Rheinland, and we want to scale it to 1.5 million pairs of jeans.
We have recently patented a dyeing process for laser-optimized fabrics in partnership with CleanKORE. These fabrics are optimized and tailor made to provide flawless wash effects for our denim products using sustainable laser washes.
Water saving has been of cardinal importance to us and is an imperative born out of the intricate self-sustainable ecosystem of CBL. To continue conserving this precious resource, we have developed an “Aqua save” dyeing technique that preserves almost 80 percent of water used in the fabric-wash stage.
We have also devised radical systems that aid in the reuse of water at the fabric-finishing stage under the name of water counter flow systems. In this process, clean water enters at the final wash box. Hot water used in the dyeing and finishing processes is residual water generated through the power generation process. Fresh water is used only for chemical solutions. Currently, we are using less than 30 liters of water per meter. In applying the complete process, this would decrease to less than 25 liters used per meter.
At Crescent Bahuman, we believe doing the right thing makes good business sense. We intend to exceed the expectations not only of our valued customers and communities we operate in, but also our employees. We are a future-focused organization and the paradigm shift of the concept of businesses being transparent and responsible is important for us.
Learn more about Crescent Bahuman Limited and its denim manufacturing processes.