SDC:

Technology Transfer Cost saving solutions for dyeing and finishing

SDC: Technology Transfer Environmentally friendly, cost saving solutions for dyeing and finishing With the pressures of competition, coupled with environmental concerns, the need to optimise all operational and production processes across the supply chain has never been greater. There is increasing pressure to deliver measurable, sustainable results. Dyehouses in the 21st century have to operate in a difficult world: Legislative initiatives to restrict the impact of the manufacturing industry on the environment may be desirable, but restrictions on production techniques create new barriers to business success. Ever stiffening quality requirements from the consumer and greater demand for production uniformity from retailers and garment makers Instrumental colour measurement and digital colour communication are essential tools in the modern dyehouse. SDC technology transfer can provide expert direction through this maze of 21st century colour physics.

What are our clients looking for? Efficiency and profitability, combined with a genuine commitment to sustainability through energy saving and good environmental practices. Our approach is based on innovation and good performance. We will optimise the performance of existing procedures. Our results are measurable and sustainable in the long-term.

About SDC SDC is the world’s leading, independent educational charity dedicated to communicating the science of colour. As the world’s longest established textile colour organisation, SDC has set the standards in best practice. Whereas individual consultants often have specialised expertise, SDC can call upon a wealth of experience from over 500 Chartered Colourists. We have a dedicated team of consultants, experts from every field of textile coloration. This gives you peace of mind in the knowledge that your partners in the project are solid, experienced professionals with a long track record of sustained success in the wet processing of textiles around the world.

What do we offer? We offer target based projects designed specifically for the individual dyehouse with full consideration for all local parameters related to utility supply, factory conditions, customer base and fabric styles and related to performance, i.e. quality, costs and environmental issues in managing colour through the supply chain. Our team will visit you to establish the need, then design, set up and implement the project that is appropriate for your needs, including how best the dyehouse can take advantage of available technology. Key areas of support include: Colour measurement and communication Laboratory management and testing Dyehouse management SDC technology transfer is supported by state of the art hardware and software tools, essential in helping to deliver results. Lead by our specialist team, our project implementation follows best practice procedures. The framework includes: An audit, to identify and establish inefficiencies in manufacturing and operational procedures Identifying and quantifying the optimal performance parameters The redesign of procedures – manufacturing and operational, based on our findings The set up and implementation of new hardware and software The development of new procedures to make best use of the available infrastructure Staff training, as required, to ensure the new systems and procedures are embedded into day to day practice The introduction of specialist tools and methodologies for monitoring and evaluating the results Implementation support for the new systems and processes, so that the benefits are achieved and maintained

What are the benefits? Whilst each project and customer is individual, the benefits you can expect are universal in terms of efficiency and the impact on profits and customer satisfaction and include:

Production and operational – benefits which can be measured, on an ongoing long term basis. The consultancy will identify and eliminate inefficiencies, and focus on maximising production levels Financial - tangible and significant savings, and maximised profitability by reducing costs, whilst not impacting on quality. Sustainable - long term benefits to the customer and the environment Efficiency at all levels of operation and production, with the adoption of best manufacturing principles Well trained staff, with a knowledge base that is deeply embedded within the organisation.

Case study examples Below, we have detailed some real examples from different dyehouses, illustrating typical situations and the significant cost savings you can expect.

Case Study One The dyehouse claimed the following cost implications of reproducibility: Cost of Dyeing per year: $US 2,562,000 Revenue of Dyehouse after admin costs etc: $US 2,760,000 Profit: $US 198,000 (7.2% on turnover) This is based on 10,000 kg per day, 300 days per year, 80% right first time on established recipes and 50% right first time from lab recipes. However, the actual situation was as follows: Cost of Dyeing per year: $US 2,637,000 Revenue of Dyehouse after admin costs etc: $US 2,760,000 Profit: $US 123,000 (4.5% on turnover) This is based on 10,000 kg per day, 300 days per year, 70% right first time on established recipes and 30% right first time from lab recipes. In other words, the actual profit was only 4.5% on turnover, with significantly lower percentages for right first time than had been claimed. In addition, the cost of dyeing per year was higher than had been reported, and the profit lower. Following the consultancy, the statistics were as follows: Cost of Dyeing per year: $US 2,430,000 Revenue of Dyehouse after admin costs etc: $US 2,760,000 Profit: $US 330,000 (12% on turnover) This is based on 10,000 kg per day, 300 days per year, 98% right first time on established recipes and 80% right first time from lab recipes.

So although the revenue of the Dyehouse remained the same, the following benefits were achieved: The cost of dyeing was reduced by over $ US 200,000 The right first time percentage was dramatically increased from 70% to 98% on established recipes and from 30% to 80% on lab recipes The profit was significantly increased from $ US 123,000 to $ US 330,000

Case study two The table below summarises the production cost analysis, and projected savings. Production Cost Analysis Cost element

Current situation

Projected situation

Savings

Steam

0.0800

0.0195

75.6%

Water

0.0505

0.0084

83.4%

Electricity

0.0193

0.0132

31.5%

Dyestuff and chemicals

0.4245

0.4118

3.0%

Labour costs (estimated)

0.0129

0.0088

31.8%

Total cost per kg

0.5872

0.4617

21.4%

0.1255

21.4%

Cost reductions per kg Yearly cost reduction

€ 325,324

Project benefits: Proper organisation of the dyehouse and related departments, resulting in the creation of a healthy environment, which will yield the best outcome from production in the available machinery Lower water, energy, dyestuffs and chemicals usage Shorter process times and therefore more batches per day High repeatability or bulk to bulk continuity More consistency in the lab operation and therefore better lab to bulk reproducibility Less operator intervention in process control Standardisation and overall control of the dyeing processes and machines settings

This resulted in the following financial benefits: Cost savings of 21.4% on the project of 7,300 kg per day Annualised cost savings of € 325,324 Further financial benefit from increased profit from higher production of € 489,000 (assuming a margin of € 0.6 per kg) In summary, the total annualised financial benefit was projected to be in excess of € 700,000

Theoretical Example The following theoretical example illustrates the potential cost savings by right first time:

A small to medium sized dyehouse processing 10,000 kg per day at an average cost of x per kg. In this commission dyehouse due to new shades or changing substrate 40% of dyeings are to a new recipe directly from the lab. At present only 30% of these new recipes are on shade after the completion of the standard dyeing cycle (although the continuity of established recipes is 80%). Of the shades requiring correction: 80% are corrected by an average of 3 shading additions and the other 20% cannot be corrected and need stripping and redyeing. The theoretical cost of preparation and dyeing is: y per kg Each addition costs 15% of y The cost of stripping and redyeing is: 145% of y including any necessary shade corrections (note: this is only carried out after attempts to correct the shade without stripping, which adds even more cost so the final cost of a stripped and redyed batch is 290% of the standard dyeing cost) The impact of improving lab to bulk reproducibility from 30% to 80% gives a cost saving equivalent to: $US 433,000

The detailed cost advantages will be different in every case, but if you substitute realistic numbers from other dyehouses into this model these kind of very significant cost savings are shown in almost every case.

Sustainabilty For the environment and the business. An SDC technology transfer project can help to reduce the impact on the environment (including a reduction in emissions) and achieve significant energy savings (including electricity and water). Overall efficiency benefits include increased daily production, a decrease in production costs and outstanding delivery against all performance indicators.

Why use SDC consultants? Value for money – achieve efficiency savings and reduced processing time Excellence – we offer objective advice and have an international reputation for excellence Independence – unlike many consultants, we are not allied with any commercial organisation selling dyes, chemicals or equipment Expertise – our consultants are acknowledged industry experts worldwide, and highly experienced within industry. We have access to broad based technical expertise from every aspect of colour application and performance testing Specialist advice – we are specialists in every aspect of dyeing and coloration Industry standards – we are the ultimate authority on standards, having commissioned and published standards and seminal texts used by textile dyers worldwide for many years Our consultancy is the result of many years of experience in working with dyehouses around the world.

Further information For further information about consultancy, please contact Andrew Filarowski, Deputy Chief Executive: email: [email protected], telephone: +44 (0) 1274 761 777

Society of Dyers and Colourists Perkin House 82 Grattan Road Bradford West Yorkshire BD1 2LU United Kingdom Tel: +44 (0)1274 725138 Email: [email protected] Charity Registration No: 212331