Color City Ltd. ( Eco Threads & Yarns ) Branding Bangladesh in sustainable sewing thread manufacturing and dying technology

Mohammad Nurul Alam

Color City Ltd. (Eco Threads & Yarns) a concern of DBL group started its journey on 20th July 2017 and is fully committed to continuous improvement by creating innovative and cost-effective solutions that protect the environment and improve lives. Integrity, Passion, Adaptability, Care, and Excellence are the five core values that Eco Threads & Yarns upholds and adheres to and offers sewing thread with robust color science, consistent quality, and the creation of values to the customers. Their goal is Sustainable Development for a better planet today and for future generations.

How to differentiate from others?

Sewing thread manufacturing units are crucial aspects of the textile industry. This industry requires innovative solutions to meet the changing demands and industry standards to stay competitive. So, Eco Threads & Yarns is geared mainly towards sustainable solutions such as recycling, waste reduction, production efficiency, and green innovations.

Rafiqul Anam, Executive Director of the Manufacturing unit of Eco Threads & Yarns said, ‘Today, clothing retail brands are focusing and pushing towards a sustainable clothing industry, and consumers are also becoming more aware and educated about sustainability, and so they are willing to make purchasing decisions based on sustainable trend. But this requires modern and cost-efficient advancement which Eco threads and yarns inherited with state-of-the-art technologies. Satisfying all these requirements Eco Thread & Yarns has introduced a series of sewing thread products in Bangladesh’.

Eco Threads & Yarns main focuses

Sustainable approach by Eco Thread & Yarns both in the product and manufacturing process:

Eco Thread & Yarns believes that if harmful processes are maintained with no change, the atmosphere will likely be irreparably damaged for Earth’s ecosystems to live. The sustainable approach by Eco Threads & Yarns is designed to conserve natural resources, support a healthy community and environment, and earn enough revenue to remain financially viable long-term.

Shiplu Chowdhury, Assistant General Manager, Marketing, Eco Thread & Yarns informed Textile Focus, “Sewing thread is a very minor component that can be about 1-2% considering the product value of ready-made garments. Instead of being such a low-value component, brands are getting involved in focusing on sustainability for all minor components. A product cannot be 100% sustainable unless sewing thread is not produced or made on a sustainable theme.”

“We successfully convinced world-renowned brands like H&M, M&S, C&A, Puma, G-Star, Uniqlo, Benetton, George, Perry Ellis, Bestseller, Zara, Target, and many more. Sewing thread is a minimal component but contributes a lot to garment quality & construction that should not be kept aside in the journey of sustainability goals. Because global water-reduction, Reducing Carbon Footprint and Zero-Waste-to-Landfill initiatives will not be successful if sewing thread manufacturing unit is not considered for sustainability’ he added.”

Innovative Product Series

Ecodenim – Denim sewing thread, is still in demand for innovation and improvement. Because a denim product has multiple destructive processes so the sewing thread should have to function strongly during the washes and long-term usage. So, Eco Threads & Yarns, with the power of innovations and its strong R&D team exhibits solutions for evolving denim constructions. Ecodenim is the sewing thread for denim that offers advantages over conventional threads (Staple spun polyester, Core spun polyester) with Bolder Outlook, Higher Seam Security, Stronger Seams, and Higher Elasticity.

Eco Corded Cotton ECOCOT Corded is a premium cotton thread made from long staple spun and mercerized cotton fiber & with special corded construction. Strong and Durable for high-speed sewing and efficiency. Provides a great seam appearance without machine adjustments,

Eco Lyocell Eco Lyocell is a 100% Tencel, fully biodegradable sewing thread. It is made from wood pulp.

Our constant commitment to innovation has produced this sustainable product for a diversified range of garment usage. It is fully biodegradable under freshwater conditions. Offers outstanding resistance to rapture & better elasticity than the other cellulosic fibers. Ideal solution for garments made with elastane and lycra fabrics.

Sustainable Product Series

The recycled product line – Made from post-consumer PET bottles, Premium Recycled Polyester with Global Recycled Standard certification. At present H&M is using 70% recycled polyester sewing threads that are produced by Eco Threads & Yarns.

Biodegradable Thread Premium Mercerized Cotton dyed with Cradle to Cradle approved Dyestuff, It offers almost Zero impact on the environment, High Color Luster, and a wide range of colors. Example: Lyocell – made from wood pulp, Biodegradable but stronger than cotton thread, Proper solution for garment over-dye program.

Organic Cotton Thread – Premium Mercerized Cotton with less water consumption, no synthetic pesticides & fertilizers to ensure very low impact on the environment.

Eco Threads & Yarns offers variety range of premium quality sewing thread

Application of modern technologies that reduce human intervention in the processes:

Industrial automation technology leads companies to higher productivity, increased efficiency, and more profitability. Aiming the automation Eco Threads & Yarns introduced all the modern technologies in its manufacturing units.

The automation system uses most modern technologies that follow complex systems and take robotic assistance in processes.

In a discussion Engr. Md. Salman Ansary, Assistant Manager, Technical Advisory Services informed Textile Focus, “Eco Thread & Yarns is a leader of industrial automation in Bangladesh for sewing thread manufacturing. We designed industrial solutions based on the best production process and business goals. Operation costs are reduced and thread quality is maintained by introducing the most advanced technologies and machinery to sustain in the competitive sewing thread market, As a result, the company has emerged as a manufacturer of global standard premium products.”

SSM (Switzerland) Winding Machine

SSM (Switzerland) Winding Machine-

Total No. of Spindle: 210

Avg. Capacity: 120000 Cones/Day

No. of Spindle by 2022-23: 380 (25% growth)

Avg. Capacity by 2022-23: 150000 Cones/Day (25% growth)

Dying Machine-

Yarn Dying Machine

Thies (Germany)

Latest state-of-the-art European machinery, Capacity Range: 1000 Kg/batch ~ 12 Kg/batch

Ugolini (Italy)

Latest state-of-the-art European machinery, Capacity Range: 6.0 Kg/batch ~ 1.0 Kg/batch

Have the Lowest liquor ratio (1:6)

Water Saving: 2x6x15000=180 m3/day, 5.4M Litres/month

Auto Dispensing Facility –

It reduces the spilling of chemicals during operation.

Also, help to reduce any unnecessary water for washing.

Water Saving: 5000 ~ 6000 Liters/month

Wet Laboratory:

The Laboratory operates fully robotic, with the precision of automatic highly productive, and

energy-efficient equipment. It also introduced zero waste generation machines to provide

unequaled value service.

Eco Thread & Yarn is reducing Carbon Footprint, Energy & Power Conservation & Environmental Protection:

Exhaust Gas Boiler- The boiler has been installed to generate steam by using hot exhaust flue gas exerted from the power generator. The hot flue gas is used for steam production without using any fuel.

  • Capacity: 2200 Kgs/hr X 5 nos.=11000 Kgs/hr. Steam produced without using fuel 9350 kgs/ hr. (Considering 85% efficiency)
  • Avg. Savings: BDT. 3090K/Month (Considering Cost equivalent to N.G, Average BDT. 0.50/Kg steam)

Heat Exchanger- Exchanges heat from hot waste water to cold treated water for heating the cold water without fuel usage. After losing heat, cold wastewater passes to ETP through wastewater-flowing pipes and saves average BDT. 250K per month.

Process Heat Exchanging- Cooling water becomes hot by exchanging heat from the dyeing machine &

RF Dryer that is utilized for drying. Reuse of cooling returned water reduces a significant amount of steam consumption.

Steam Generator

Integrated Facility:

  • The economizer has mounted in Every Steam Generator
    • Reduces 30% Fuel Consumption
    • Saves BDT 0.35/Kg steam production

Condensate Return Facilities:

  • Reduced 15% Fuel Consumption
    • Saved BDT 0.13/Kg Steam Production

Effluent Treatment Plant: A biological ETP for the treatment of colored wastewater. This automated wastewater treatment plant converts harmful wastewater into ecologically friendly freshwater that does not cause any harm to aquatic animals, plants, and crops

Rainwater harvesting eco threads

Rainwater harvesting: The Factory is equipped with a rainwater harvesting facility that reduces 10% of water consumption.

Water Saving: Avg. 1850 m3/Monsoon,

185,000 Litres/year.

Energy & Power Conservation: With the initiative of Variable Frequency Drives, Renewable Sources- Solar Panel, Daylight Saving, LED & Integrated Facility. This is the use of Sunlight during the daytime that could save 1462 KWH/ month of electricity consumption.

Environmental Protection: Effluent Treatment Plant, Secondary Containment & Integrated Facility where Economizer is used in all boilers to exchange heat from hot flue gas to feed water. Hence, it reduces the temperature of hot flue gases from about 220⁰c to 120⁰c before releasing them into the atmosphere.

Additional General Manager, Engineering, Thread & Accessories Division of Eco Thread & Yarns Sujaul Islam explained in detail to Textile Focus how carbon emission is designed to reduce. He said, “We believe making small changes for a better life can make a big difference in the future. Our experts found many ways to reduce carbon emissions in the manufacturing unit. We designed to save energy by a mechanism that helps to reuse energy generated from various industrial processes. Exhaust Gas Boiler, Heat Ex-changer & Integrated Facility can help limit the impact of carbon emission on the environment.’

Pre-sales & After-sales Services by Eco Thread –

Ecocare- Under which Eco Thread & Yarns offers a wide range of technical assistance for manufacturers and buying offices. Their premier focuses are on:

  • Thread Consumption
  • Thread costing analysis
  • Thread & Needle selection
  • Troubleshooting & Development Assistance
  • Workforce awareness sessions
  • Hidden cost analysis
  • Productivity improvement program
  • Vendor-managed inventory (VMI) program

In conclusion, it is high time to pursue brands and manufacturers to embrace a more sustainable approach to saving life and the earth. As a sewing thread manufacturer, Eco Thread & Yarns is committed to creating innovative solutions for the textile industry which improve lives and sustain the planet. This will help brands to make the right sustainable choice fitting their needs. So, to lead the sustainable manufacturing process and produce sewing thread Eco Thread & Yarns plays a significant role.

Colorcity Management
(From Left – Rakibul Islam, Textile Focus; Engr. Md. Salman Ansary, Assistant Manager, Technical, Rafiqul Anam, Executive Director; Sujaul Islam- Additional General Manager, Engineering; Mohammad Nurul Alam, Textile Focus & Shiplu Chowdhury, Assistant General Manager, Marketing of Eco Thread & Yarns.