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Indorama Ventures, DyeCoo & Stoll team up for masks

May 27, 2021
Indorama Ventures, DyeCoo & Stoll team up for masks

Reutlingen, Germany

Indorama Ventures, DyeCoo and Stoll (a part of KARL MAYER Group) have announced a collaborative effort to produce a fashionable mask called Easy Mask. The mask is made by a sustainable production process, starting from the yarn production to the dyeing, design and production.

Indorama Ventures is one of the world’s leading petrochemicals producers. DyeCoo is the world’s first commercial supplier of water-free and process chemical-free dyeing systems for polyester textiles. Stoll is a reliable manufacturer of efficient flat knitting machines.

Face masks are currently in demand to combat the COVID-19 pandemic and help in mitigating the spread of the virus. But, they contribute to environmental problems such as waste and pollution.

The advanced technologies of the three companies ensure that Easy Mask does not just eliminate waste, but also reduces the use of water and energy. The design approach ensures that all components can be easily removed and reused for other masks.

Deja is the sustainable recycled polyester brand from Indorama Ventures. The polyester performance yarn is made from 100% post-consumer recycled PET bottles and can be used for a multitude of home and apparel applications. The yarn is independently certified and traceable, with full transparency across raw material and processes including GRS, Ecomark, RCS, Oeko-Tex 100 and Reach. Locally sourced 100% post-consumer rPET products offer a low-carbon footprint and closed-loop solution. Deja is 100% recyclable at the end of use and can be repeatedly re-processed without harmful emissions or discharges to create new high value-added products.

The Deja recycled yarn is dyed afterwards with the innovative supercritical Carbon Dioxide textile dyeing technology by the Dutch company DyeCoo at CleanDye factory. The sc-CO2 dyeing machines can dye yarns or fabric rolls in a closed-loop process without using water and process chemicals, thereby producing any wastewater. By using only the pure non-toxic Corangar dyestuff made by Colourtex, in combination with sc-CO2 that is 95% reclaimed in the machine, textile dyeing has less of an environmental impact compared to traditional dyeing technologies. As Carbon Dioxide has the same quality every day and over the whole world the technology is reliable and reproducible.

EASY MASK is a fresh approach to reinterpret a traditional medical facemask from a design perspective. It is a 3D knitted and playful kinetic object that expands and collapses easily. It is simple to use and comfortable to wear; be it over the face or around the neck. The design approach allows customisation, on-demand production, and reduces production waste to below 1%. Integrated ventilation increases breathability. Whilst it does not protect the wearer from infection it limits the spread of viruses.

Both the production method as well as the design itself takes environmental and sustainable aspects into account. Washing at 60°C makes repetitive use possible. All mask components (metal bar, knitted strings and adjustment tube) can be easily removed and reused for other masks.

The mask is knitted on a STOLL CMS 530 HP B E 7.2 machine, but can also be knitted on other types of STOLL machines. This allows for flexible local production independent of the machine park.

Source – Stoll - Karl Mayer Press Release

Image Source: Stoll - Karl Mayer Press Release

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