TRL: 7

D(y)ENIM: Ultrasonic application system for denim yarn dyeing

Step:

 Colouration

Applications:

Raw Material:

 Cotton yarn

Construction:

 Knit

 Woven

Replacement for:

 Standard indigo slasher or rope dyeing 

Sonovia’s proprietary D(y)ENIM® process allows dye particles to be physically forced deep into fibre structure in a single dye bath, eliminating the need for chemical binders, redox or hydrosulfite treatments, and pre‑ or post‑washing cycles.

Substrate Tested:

Raw Material:

 Cotton

Construction:

 Yarn

Benchmarks:

Commercial slasher dyeing

Location: Italian, Pure Denim

Scope:

 Dyeing

Key Findings: 

• D(y)ENIM® eliminates the need for pre and post wash baths and large dipping baths required for conventional denim dyeing. Only one bath is needed to dye the yarn.
• Existing slasher dyeing ranges can also be replaced with Sonovia’s D(y)ENIM® process as there is no requirement of prewashing and post washing lines.
• 84.54% savings in total chemical consumption
• Sonovia speed is 25 m/min compared to 10m/min for the conventional slasher dyeing, which leads to 17% savings in production time.
• The machine requires only one operator, compared to the usual three needed for conventional setups.

Performance: At the yarn dyeing level, the performance is comparable to conventional slasher dyeing. However, overall performance at the garment level (e.g. finished jeans) will depend on several downstream factors, such as the type of garment washing and finishing processes applied.