As we enter the second year of the worldwide COVID-19 pandemic there is a continuing need for masks. While face masks help greatly in mitigating the spread of the virus and protecting the wearer, they also contribute to environmental problems such as waste and pollution.
EASY MASK is a collaborative initiative between Indorama Ventures, DyeCoo and STOLL to produce a fashionable mask with a sustainable mind-set throughout the whole production process – starting from the yarn production and followed by the dyeing, design and production. With the advanced technologies of the three companies, the 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 re-used for other masks.
Deja™ recycled polyester
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 afterwards dyed 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 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.
Design and Production
The sustainable product advantages achieved through the use of Deja™ recycled polyester and CO2 dyeing technology are further enhanced with the design and production method.
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 customization, 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, take environmental and sustainable aspects into account. The seamless production method eliminates cut and sew and reduces waste material whilst offering customized on-demand production to lessen product surplus. Washing at 60°C makes repetitive use possible. All mask components (metal bar, knitted strings and adjustment tube) can be easily removed and re-used 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.
Indorama Ventures Public Company Limited, listed in Thailand (Bloomberg ticker IVL.TB), is one of the world’s leading petrochemicals producers, with a global manufacturing footprint across Europe, Africa, Americas, and Asia Pacific. The company’s portfolio comprises Combined PET, Integrated Oxides and Derivatives, and Fibers. Indorama Ventures products serve major FMCG and automotive sectors, i.e. beverages, hygiene, personal care, tire and safety segments. Indorama Ventures has approx. 24,000 employees worldwide and consolidated revenue of US$10.6 billion in 2020. The Company is listed in the Dow Jones Emerging Markets and World Sustainability Indices (DJSI).
Indorama Ventures is headquartered in Bangkok, Thailand with global operating sites in EMEA: The Netherlands, Germany, Ireland, France, UK, Italy, Denmark, Lithuania, Poland, Czech Republic, Luxembourg, Spain, Turkey, Nigeria, Ghana, Portugal, Israel, Egypt, Russia, Slovakia, Austria, Bulgaria. Americas: USA, Mexico, Canada, Brazil. Asia Pacific: Thailand, Indonesia, China, India, the Philippines, Myanmar, Australia.
The Dutch company DyeCoo Textile Systems BV has developed, optimized and commercialised the use of Carbon Dioxide to dye fabrics in the last 10 years and recently also to dye yarns. By utilizing supercritical CO2, the process eliminates water from the dyeing process, in a closed loop dyeing system. DyeCoo is the world’s first commercial supplier of water-free and process-chemical free dyeing systems for polyester textiles. Using CO2 dyeing will eliminate the use of water, reduces energy consumption, eliminate chemical usage and is cost effective.
Family brand STOLL represents the KARL MAYER Group‘s expertise in the field of flat knitting technology. Since its foundation in 1873, STOLL has always been a reliable manufacturer of efficient flat knitting machines. Equipped with intelligent software solutions for patterning and production planning, such as knitelligence®, today’s models open up new possibilities of digitalisation for the company’s customers. In addition, STOLL has made a name for itself as a constant and innovative trendsetter for the textile and clothing industry in the fields of fashion and technical textiles.