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Denim Mills Invest to Streamline Production

As denim mills begin to showcase their Fall/Winter 2024-2025 fabric collections, they’re sharing how recent investments in technologies and machinery are streamlining (and greening) their production.  

“From farm to fashion, the ethos at Artistic Fabric Mills is to consistently invest in better practices, processes and the people that make it all a possibility,” said Haya Iqbal Ahmed, Artistic Fabric Mills director. 

The mill has invested in organic cotton farming in collaboration with WWF Pakistan. Through the program, Artistic Fabric Mill will cultivate barren land into organically grown crops and elevate local communities by working with farmers, women and children to implement skill development and literacy programs, as well. 

The company is also investing in new machinery. “On the factory floor, we are gearing up to produce bi-stretch fabrics with specialized equipment as part of our expansion plans that will increase our capacity by 75 percent,” she said. 

“[Today’s jeans] can be created in a better and more proactive way,” said Rashid Iqbal, NDL executive director of marketing. “NDL is taking measures and working on developments with a vision of going carbon neutral by implementing sustainable approaches in its processes and selection of raw materials.”

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Carbon Zero Tencel is NDL’s step towards decarbonization, creating denim that is functional, sustainable, and traceable. The mill’s Re-jean’erate collection combines post-consumer waste (PCW) cotton and sustainable blends to “create a better fashion for tomorrow.”

Soorty is investing in ways to grow its resources. In addition to adding more renewable energy sources, the mill is expanding its capacity from 6 million meters per month to 8 million meters. Its recycled cotton (PCW) plant is churning out an additional 150 tons per month for a total of 450 tons per month, and its spinning capacity is growing from 1,800 bags per day to 2,800 bags per day. 

Naveena Denim Mills is also growing and sourcing organic cotton in Pakistan. In partnership with WWF, Naveena has launched a new project covering 10,000 hectares of land, providing know-how and seeds to more than 500 farmers.

To further reduce its carbon footprint, the mill recently established Lakeside Energy Limited, a 50MW wind power project aiming to provide renewable energy to more than 250,000 households in Pakistan. The mill is also implementing a state-of-the-art solar energy system that will generate 7.5MW, according to Berke Aydemir, Naveena Denim Mills head of R&D and technical sales.

“We continuously invest in new equipment and sustainable upgrades and this year is no exception,” said Scott Gress, Siddiqsons president, North America. He said the mill has increased its solar energy output by 50 percent and it is monitoring processes on an ongoing basis to “see where we can improve even further.” 

Global Denim’s investment in a water recycling plant and caustic soda recovery system allows the mill to save water and energy. Its new project, however, will foster creativity. New finishing machinery allows Global to experiment with color, pigments, reactive dyes, sulphur, polyester dyeing, phosphorescent colors and weft dying. 

“This will allow us to follow the actual trends and deliver brand new developments that cater to a more premium audience as well as a more creative youth-oriented consumer,” said Anatt Finkler, Global Denim creative director.

Cone continues to maximize the use of its investments in Jeanologia’s G2 Dynamic ozone finishing range in China and Mexico. 

Additionally, the company recently established a certified supply chain for recycled cotton in Mexico. “We are not new to RCS [Recycled Claim Standard]; we have just invested in closing the loop further and successfully becoming certified in Mexico. This is the next step in our sustainability journey for cotton fiber, with more to come,” said Pierette Scavuzzo, Cone Denim design director.