“As Jeanologia, We Started the Era of Air Washing in Textiles”

Interview: Dilek Hayırlı

Jeanologia Director Manager Carmen Silla said, “With the revolutionary Atmos washing process we are exhibiting at our booth, as Jeanologia, we closed the water-washing period in the textile industry and started the air period.”

Jeanologia is an innovative and multicultural company with over 25 years of experience in developing sustainable and eco-efficient technologies for the garment finishing industry. Jeanologia technology is used in more than 35% of the 5 billion jeans produced worldwide each year. The company, which has customers on 5 continents, opened the way to a cyclical, zero-discharge industry at the ITMA 2023 Exhibition, exhibiting Atmos, a revolutionary process that ends the water era in the textile industry and uses only air to achieve an authentic vintage look.

As Tekstil Teknoloji magazine, we visited the Jeanologia stand at the ITMA 2023 and had an interview with Carmen Silla, Marketing Director of Jeanologia

As Jeanologia, you exhibited the atmospheric washing process Atmos at the ITMA 2023. What are the advantages and benefits of this new product for the industry and users?

As Jeanologia, we started the air era in the textile industry with our revolutionary Atmos washing machine that we exhibited at our stand. Our Atmos atmosphere washing  process that achieves natural aging of garments and stone wash look without water, chemicals or pumice stones, replacing traditional water washers with air washers. With our G2 ozone technology and our INDRA patented system, which achieves perfect control of the humidity and atmosphere temperature, we attain the same effects that were previously only possible with water, chemicals and pumice stones, while ensuring perfect reproducibility and enhanced productivity in a more efficient, sustainable and safe way. When we first introduced laser technology in 1999, we eliminated the sun blasting and potassium permanganate spray. And now, thanks to Atmos, we have eliminated water, chemicals and pumice stone.

What was the reaction of the visitors to Atmos during the ITMA? Are you satisfied with the interest?

The reaction to our product during the ITMA Exhibition was quite positive. Everyone said it was great when it comes to products, results, water, chemicals and time savings. I think it will be highly demanded by all brands, retailers and their suppliers starting next month.

Can you tell us about the products developed by Jeanologia for water, energy and cost savings?

We also presented latest developments in advanced lasers for garment finishing which has positioned it as the fastest laser technology on the market. Up to 40% faster than other lasers, it achieves maximum productivity, reduces operating costs and accelerates time-to-market to ensure the lowest cost-per-garment. In addition, it enables more efficient energy management, simplifies processes and offers infinite design possibilities with high quality authenticity and perfect reproducibility.

Other technologies contributing to the paradigm shift in the textile industry are Jeanologia’s eco-efficient DancingBox 420 high-speed water washers. Thanks to its patented system, they attain better product abrasion in less time and with less water, achieving higher productivity, while improving the performance of e-Flow, its technology based on air nanobubbles to transport chemicals to the garment instead of water.

Finally, with H2Zero, the company comes full circle by repurposing the small amount of water needed for garment finishing. A closed-loop water treatment system treats water without chemicals, leaving it in optimal conditions for later reuse, thus completely eliminating discharge from the textile industry.

Together with Inditex, you developed the Air Fiber Washer, the first industrial air system designed to reduce microfiber shedding in textiles. What advantages does this product offer to users?

As we Inditex and Jeanologia have jointly developed Air Fiber Washer, the first industrial air system designed to extract microfibers during garment fabrication and thus reduce subsequent shedding in domestic laundering. Microfibers are small particles with a length of less than 15 millimeters that are shed from textiles, especially during initial domestic washes. This is one of the great challenges for the textile industry due to existing limitations in current industrial capacities for water treatment. Air Fiber Washer was created with the aim of reducing the release of microfibers in initial washes thanks to a new industrial pretreatment that effectively removes these particles. With innovative technology, this new development makes it possible to reduce microfiber shedding by up to 60% through the use of air, without employing water or thermal energy and without compromising aspects such as fabric quality. Its dynamic air flow extracts the microfibers from the garments and collects them in a containment bag for potential recycling, moving us closer towards a circular industry with zero waste. Each Air Fiber Washer will collect up to 325 kg of microfibers per year, depending on the type of fabric, and machine conditions such as loading and movement.

ITMA focused on automation, digital future, sustainability/circularity and innovative technologies. What is your priority as Jeanologia?

In terms of sustainability and digitalization, we have a concept we call Laundry5.Zero. With this concept, which is a combination of G2 ozone, laser, DancingBox 420, e-Flow and H2Zero, we can automate the process to reduce the amount of water and chemicals. This means we’ve eliminated all manual processes. By integrating and connecting all of its technologies in Laundry5.Zero plants, the our company facilitates new production models that bring about five benefits for a new era in the textile industry: eco-efficiency, cost-neutrality, scalability, agility and digitalization.

We also introduced Handman, our automation laser robot technology, at the ITMA 2023. Automation laser and robotics technology for denim production, where humans and robots work together to achieve sustainable, scalable production. Thanks to this technology, we can produce more than 8,000 garments per day.

Digitization solution, we have software called eDesigner so you can create virtual collections. Which means we’ve eliminated the sampling fence and avoided it. So you can reduce about 80% of the samples.

What industrial and economic challanges are currently impacting your company, and how are you responding to them?

I think the period we are going through is very difficult not only for the textile sector but for all sectors. Because we are going through a variable process. We try to minimize the effects of this process with innovation and automation. Because our ultimate goal is; reduce cost and at least introduce cost-neutral technologies. For this, we eliminate dangerous practices for employees, reduce environmental impact and develop products that reduce costs.

Which are your major markets?

Our biggest markets are; Bangladesh, Pakistan, Turkey, Egypt, Morocco, Mexico, Brazil. As a company, we sell our products in 75 countries. Thanks to this new laundry that we have automated, I believe we will recover the industry in Europe and the United States. But the main markets for us are; Bangladesh, Pakistan and Mexico, Türkiye.

Can we listen from you about the importance of the Turkish Market for Jeanologia?

Turkey is a very important market for us that is growing day by day. We have a production, a research, a development and a demo center in Turkey. For more than 20 years, we have been working to increase automation and sustainability in the Turkish market and to realize cost reduction. We work with major players and retailers in the industry to bring the Turkish market to a more efficient and competitive position for the textile industry.

How was the year 2023 so far for your company? Can you evaluate it in terms of your orders and export markets?

The year 2023 is going well for our company so far. There is a crisis situation in the world, so some of our customers are more cautious. We are working to obtain a product that reduces costs on the production side. As a company, we are optimistic that the year will go well.