At Sharabati Denim, we have a longstanding commitment to environmental sustainability, and are among the leaders of the sustainability movement in North Africa. We focus on the areas where we stand to make the greatest difference; conserving water and improving wastewater quality, optimising our use of energy, and managing chemicals responsibly. We are also placing an increasing focus on sustainable raw materials, recycling and closed loop manufacturing. We adhere to international standards on health and safety, quality, chemicals and sustainable materials (Compliance).
Conserving water and improving water quality.
We use water for manufacturing, dyeing and finishing fabrics. To help conserve local water resources and prevent pollution, we are investing in technologies and processes to save water and treat wastewater effectively. This includes water-saving manufacturing lines, dyeing materials, and installing chemicals recovery and water treatment units.
Treating wastewater effectively
In Egypt, we conduct effluent purification in wastewater treatment plants through a purpose-built biological treatment plant. The quality of the wastewater discharged is monitored internally, verified by independent laboratories and meets legal requirements.
Saving water in denim dyeing and finishing
We have steadily decreased the volume of water we use in denim dyeing by adding multiple water-efficient rope dyeing lines, and updating and automating the dyeing lines we use for denim finishing.
Innovations in water-less dyeing
We are exploring best practice in waterless dyeing. In particular, we are using sustainable dyes (compatible with GOTS and Bluesign certification), producing zero effluents and saving water.
Caustic Recovery Plant (CRP)
Our CRP recovers used caustic soda from the mercerising wastewater for reuse in our production. We use the heat generated to heat water, saving natural gas, and recapture the water evaporated from the CRP, reusing it in the mercerising machine.
Optimising our energy use
We use electricity through our production facilities. We are making energy savings by adding modern energy-saving machines, and taking steps to save energy in our office buildings.
Saving electricity in denim finishing
After weaving, we treat denim fabric in order to achieve the right feel and correct dimensional stability, helping to prevent shrinkage in future washing. Our continuous denim finishing line saves water, steam and in particular, electricity, compared to conventional lines.
Energy saving at our head quarters and factory offices
We have modified the air conditioning system at our Egypt headquarters to operate more efficiently and promote a healthy working environment. Similarly, we have replaced conventional air conditioning systems with energy-efficient evaporative coolers (desert coolers) at our new factories.
Saving electricity in spinning mills
We select our spinning machines primarily on the basis of energy-saving criteria, and have made substantial savings at our spinning mills in Egypt, while expanding production.
Reducing heating requirements in denim dyeing
We reuse condensate return water and opt for cold dyes that require less heating in the dyeing process, saving significant amounts of natural gas. We also save electricity by using cold dyes, and take measures to save both electricity and water in the laundry washing process.
Managing chemicals responsibly
Chemicals are used throughout garment and textile production to dye fabrics and give them particular performance characteristics. We are moving beyond compliance and reduce our use of chemicals by using more sustainable dyes and re-engineering dyeing processes, and installing chemicals recovery and water treatment units.
Reducing chemical use with pre-reduced liquid indigo
We were among the early adopters of the pre-reduced liquid indigo dye, a progressive process for the production of standard blue denim fabrics. This reduces our direct chemical use and is consequently safer for our employees, who avoid handling the chemicals previously used in conventional powder indigo dyeing.
Managing chemicals in rope dyeing
We operate multiple rope dyeing lines to prepare and dye warp yarn denim. Compared to slasher dying technology (the most widely used technology), rope dyeing allows us to make savings in washing water and chemicals.
Opting for more sustainable sulfur dyes
We are replacing the reducing agent within the sulphur dyeing process with more environmentally sustainable reducing agents.
Improving wastewater quality through efficient sizing
By adopting a new sizing method in our factories, we are saving sizing materials and electricity, and creating a safer work environment. This method also allows us to reduce the chemicals and water needed in the desizing process, which in turn improves the quality of our wastewater.
Switching to safer substances for desizing
We have improved the sustainability of the desizing process by switching from enzymatic (non-soluble starch) to non-enzymatic (soluble starch) desizing. In addition, by modifying our desizing method, we have achieved considerable savings in desizing materials.
Reusing yarn carriers
Our integrated production allows us to reuse durable yarn carriers (cones and layers) for spun yarns several hundred times. By using carriers made of durable materials instead of paper, we are also saving significant volumes of paper at our spinning mills.
Recycling e-waste and promoting rechargeable batteries
We have partnered with RecycloBekia to recycle our electronic waste and remove any data from end-of-live machines safely and sustainably. To protect the environment and save costs, we also use rechargeable batteries in preference to single-use batteries.