Equipped with the best facilities to move towards carbon neutrality
Rain water harvesting
The practice of collecting and storing rainwater, rather than allowing it to run off and go to waste
1
Rooftop Harvesting
2
Fullfils 25% of ground water requirement
3
A step towards water neutrality
Waste water management
Process used to treat, recycle and dispose of waste water in a sustainable manner
1
Effluent treatment plant - Designed to handle 400KLD of waste water based on membrane bioreactor
2
Reverse Osmosis - Multistage technology with sea water type Dumont membrane
3
Zero Liquid Discharge - 30KLD ZLD system with MVCC technology having lower carbon footprint
Renewable energy
Energy derived from naturally replenishing resources that are virtually inexhaustible on human timescales
1
Photovoltaic Cells - 15% of power is generated from PV cells
2
Waste heat recovery - 50% heat from processed hot discharges is captured, thereby reducing steam consumption
Process
From fibre to yarn Sequential operation using various equipment to convert flax to yarn
1
Preparatory system - Mackie
2
Bleaching plant - Loris Bellini
3
Autoconer - Reiter X6
4
Ring Frame - Russian L8 & L5, Linmack by Mackie, Semi-wet by NSC
Raw material
The Raw material is scutched long flax fibre from 100% European origin, separated from flax straw by a mechanical process called scutching.
Hackling
First mechanical process where Scutched flax is guided through combs to refine fibres, remove impurities to create hackled sliver and hackled tow for yarn production.
Long fibre drawing
Hackled sliver undergoes repeated doubling and drafting processes to enhance uniformity and fineness, resulting in finisher sliver.
Carding
Hackled tow is carded to open fibres with rotating pinned rollers, removing impurities and forming a continuous sliver of clean fibre.
Combing
Carded sliver is combed to remove short fibers, then gilled multiple times. The finisher sliver is spun into semi-wet spun yarn or processed into roving.
Roving
Finisher sliver from long or short fibres is drafted, twisted into thinner roving strands, and wound on perforated bobbins for bleaching or boiling.
Bleaching
Flax rove bobbins are chemically treated in hot water to remove natural impurities, improving fibre fineness for high-quality linen yarn production.
Warm water spinning
Process where fine strands of fibre are drafted and twisted to and passed through warm water to make chemical free yarn.
Semi-wet spinning
The finisher sliver from the long/short fiber system is spun into chemical-free coarser home furnishing yarn, conserving 95% of water.
Traditional wet spinning
Bleached & boiled roves are spun into chemical free fine apparel yarn or warm water spun yarn for furnishing, saving 70% water.
Drying
Ring spun yarn bobbins are dried with radio frequency technology, then conditioned for moisture uniformity from ambient conditions.
Autowinding
Dried and conditioned yarn is auto-wound, faults are electronically detected & ends are spliced to create continuous yarn.
Packing
Each yarn cone is inspected for defects by experienced personnel before being packed into cartons for sale.
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