MILL

The most sustainable mill on the planet

01 MM

Annual capacity

019

Jobs created

02

Solar panels

Enabling a full circular manufacturing system

The integration of the fabric mill into our value stream establishes Saitex as the most sustainable seed to shelf organization on the planet.

Innovative Product Creation Center

Our PCC as a world-class R&D center, with the capability to create and prototype the first garment samples within the fabric mill.
Providing the full garment production from cutting, sewing, lasering, and washing.

Inside the Mill

Our mill’s machinery uses less energy, fewer chemicals, and less water creating the most environment-friendly processes.

Cotton & Blending 01
Spinning 02
Indigo Reduction 03
Rope Dyeing 04
Weaving 05
Finishing 06

Cotton & Blending

Partnerships with organic, recycled and transitioning cotton farmers supply Saitex Mill with raw materials. From there, the cotton bales are blend:

  • Specialized in multiple blending
  • Sustainable organic cotton & recycled fibers as well as high-tech synthetic fibers
  • Development of new sustainable blends with alternative fiber sources
  • German technology from Truetzschler for blow room, carding, drawing

Spinning

With ring spinning technology from Toyota, Japan. Roving from Electrojet, Spain. And Winding Savio, Italy. Our spinning capabilities allow the blending of different materials. Allowing us to do combed yarn, slab yarn, siro yarn, compact yarn, dual-core and triple-core.

Indigo Reduction

By using the electro-chemical reduction called the Smart-Indigo™ system by Sedo to develop hydrosulfite-free indigo dye baths in which the yarn is rope dyed. The Smart-Indigo™ system utilizes an electrochemical dye bath preparation that emits 90% less CO2, consumes 70% less energy, and 30% less water where the only waste product is oxygen. All of this while still maintaining high color consistency.

Rope Dyeing

The Mill uses Karl Mayer rope dyeing machines which use less energy to achieve the same result by dipping the rope into fewer dye baths than with standard machines, which translates into a minimum 30% reduction in indigo and chemical usage.

Weaving

The one hundred sixty rapier looms from Picanol, Italy. Coupled with knotting and drawing in from Groz Beckert, Germany. Allow for high speed precision weaving, and creating the best quality woven fabrics ready for denim and PFD weaving.

Finishing

From singeing from Osthoff to mercerizing and pad steam from Goller. Pad Batch dyeing from Benninger and fabric tumblering from Pentek. Stentering and sanforizing from Monforts. Our world-class finishing engineering solutions provide excellent quality, performance with limited ecological impact.
Future-proof, our current structure allows us for greater flexibility and capacity to invest into new technologies for future trends.

Zero fresh-water input

In our dyeing facilities, while the state of the art machinery allows us to use 30% less water. We also use no freshwater but recycled water in cooperation with the industrial park. This is possible through reverse osmosis and ultrafiltration technology.

Sustainability Highlights

4 MW
solar installations
40% of the steam generated with industrial sludge
Closed water cycle with Zero fresh-water input
Smart-Indigo™ system with hydrosulfite-free indigo dye baths
Organic, Recycle and Regenerative Cotton. Environment friendly manmade fibers

Regenerative agriculture

Within the mill compound, a hydroponic farming system and organic farming fields occupy 40% of the space and will produce 6 tons of clean vegetables per year to feed employees and local communities.

Carbon Neutral by 2025

6,000 trees were sowed in the industrial park and 50 hectares of mangroves were planted in the country to offset carbon emissions, helping to progress the Saitex Mill towards carbon neutrality by 2025.

We would dye working with you!