Tejidos Royo Waterless Denim Dyeing Process Adopted By Gap And Wrangler

Image Courtesy of Tejidos Royo

Image Courtesy of Tejidos Royo

Aware of the need for change in the textile industry, TEJIDOS ROYO, in collaboration with Gaston Systems Inc. and Indigo Mill Designs (IMD) has managed to modify the process of conventional indigo dyeing, creating a unique dyeing process capable of dyeing without water , minimizing significantly its environmental impact and obtaining a unique color in the market.

American engineering and Spanish crafts join forces and give life to the DENIM REVOLUTION OF THE XXI CENTURY.

"The idea, of course, is for the world to use this technology to democratize responsible denim," says José Rafael Royo, "making the fashion industry more sustainable is a joint responsibility"

The innovative new process, called Dry Indigo®, can reduce water usage by up to 99%, while also using 89% less chemicals, reducing energy usage by 65%, and eliminating water discharge when compared to the traditional slasher indigo (or sheet dyeing) process.  

Utilizing a foam dye that adheres to yarn, the transformative Dry Indigo® technique produces a denim fabric that is comparable in hand-feel, aesthetic, performance, and washability to traditionally dyed denim.

The foam-dyeing technique occurs in a space of less than 65 feet – compared to the hundreds of feet that is typically necessary for a traditional dyeing machine – thereby significantly reducing energy needs.  

Gap Inc’s used this technology initiative to produce denim using a waterless, indigo foam-dyeing technique, and started with a partnership between Banana Republic and Spanish denim mill, Tejidos Royo. 

 “Leveraging this revolutionary new dyeing process directly supports Gap Inc.’s manufacturing goal to conserve 10 billion liters of water by the end of 2020, as well as Banana Republic’s recently unveiled sustainability goals to produce eco-friendly denim, reduce water impact and promote cleaner chemistry,” said Gap Inc.’s EVP of Global Sourcing, Christophe Roussel. “Tejidos Royo is a trusted partner and true pioneer in sustainable innovation.

We are thrilled to work with them on this exciting new venture and have no doubt that this will change the future of denim manufacturing.” 

The Banana Republic denim with Dry Indigo® will be available through a special collection for both men and women in Spring 2020.

Tejidos Royo also welcomed The Wrangler® brand, part of Kontoor Brands, Inc. as it introduced the first denim apparel dyed with foam, a revolutionary technique that uses 100 percent less water than conventionally-dyed denim*.

 The global product launch of foam-dyed denim follows the Wrangler brand's Indigood™ commitment to discover and implement throughout its supply chain the most sustainable ways for dyeing denim.

“Indigood™ raises the bar on what consumers can expect from us in terms of environmental performance”

 “We’re proud to have helped pioneer a technology that has the potential to revolutionize sustainability standards for denim,” said Tom Waldron, VP & Global Brand President, Wrangler. “The introduction of Indigood™ foam-dyed denim represents our continued commitment to use our global scale to advance the denim industry, while maintaining the authenticity, quality and style that consumers expect from Wrangler.”

 “Indigood™ raises the bar on what consumers can expect from us in terms of environmental performance,” said Roian Atwood, Director of Sustainability at Wrangler. “We are continuously looking for opportunities to improve the sustainable impact of our products from field to seam and we are proud of what we’ve promised to achieve through Indigood™.”

The Indigood™ products will be featured in the ICONS Collection, giving consumers access to the Wrangler brand's most iconic products with the highest level of sustainability available on the denim market today.