BRFL Textiles devlops sustainable dyeing process

BRFL Textiles Pvt Ltd(BTPL), home to
India’s largest single-roof state-of-theart
fabric processing facility, has set a new
benchmark in sustainability by
introducing a new sulphur dyeing process
by continuous dyeing method that does
not require water. BTPL is the first
company in the textile sector to
implement this new process of dyeing, making them the
pioneers of this innovative sustainable process.

As a sustainable manufacturing unit, BTPL, since
inception, has taken efforts to limit carbon emission and
increase water recycling through multiple ways. The
current efficiency of the reverse osmosis unit at BRFL
Textiles’ Tarapur plant facilitates the unit to reuse 50% of
the effluent water, enabling the plant to recycle upto 4
million litres of water per day. The company is looking to
further strengthen this efficiency and aims to increase the
water recycling level to 90% in the next 3 months,
enabling the plant to recycle upto 7.2 million litres of
water per day. Additionally, most of the reactive dyeing
processed in the plant is undertaken with e-control
process, thereby avoiding salt which in turn avoids
increasing the TDS content of water.

BTPL also uses its energy co-generation design at its
Tarapur plant, which enables it to reuse 48 tonnes of steam
per hour, and save 250 tonnes of coal per day, leading to a
significant reduction in carbon emissions that exceed even
the sustainability benchmarks of global textile companies.

BTPL implements its sustainability measures across its
products as well. A majority of the fabrics produced by
BTPL, such as linen and cotton, are sold in its natural form,
making it a part of the sustainability chain. Likewise, a
large part of the linen and linen blended collection is
produced by maintaining a natural fibre colour without
adding any dye or colour to the fabric. In addition to this,
the polyester blended fabric produced by the plant is made
using recycled polyester.

Speaking on the sustainability measures of the plant,
Prashant Agrawal, Managing Director at BRFL Textiles Pvt
Ltd (BTPL), said, “At BTPL, we are committed to adopt a
sustainable approach across our company, and we will
continue to accelerate the sustainability drive as we
expand our output and market presence. Today,
greenhouse gas emission and scarcity of potable water
represent a substantial sustainability challenge across the
world. We are proud to combat both these areas through
our state-of-the-art processes that set new sustainability
benchmarks across the global textile industry and enable a
more sustainable future for our vast global customer base.

We are also hopeful that the Indian textile industry
strengthens its focus on the need for sustainability in the
sector and encourages and supports companies in the
sector to innovate and adopt sustainable
practices across operations.”

BTPL was recently formed as a
separate entity in August 2020 as part of
a restructuring process undertaken by
Bombay Rayon Fashions Limited, in
which it hived-off its yarn dyeing & fabric
processing units located in Tarapur, into
BRFL Textiles Pvt Ltd (BTPL) by way of a slump sale on a
going concern basis and attracted private equity funding
for growth. The Company’s brands, including Bombay
Rayon, BRFL, Linen Vogue, Giza Classe, Dickens & Browne
and others, were also a part of the transaction.

BRFL Textiles is engaged in processing a wide range of
fabrics at its plant located at Tarapur in Maharastra, India.
With its annual processing capacity of 144 million meters
(400,000 meters per day), the Tarapur plant is the largest
single roof fabric processing unit in India adequately
supported by its captive power, effluent treatment, RO
water and other utilities enabling cost competitiveness. It
also has a captive yarn dyeing unit with annual capacity of
10.6 million kg (29 tonnes per day).