Ÿ Vertical integration: At its Vietnam site, SAITEX Mill integrates spinning, weaving, dyeing, finishing, and garmenting under one roof—atruecircularsetup .
Ÿ Laserdistressing&ozonewash:3Dlaser and ozone-enabled washes in both Vietnam and L.A. replace manual, chemical-heavy processes —e.g.,distressingin90 svs.20–30 minmanually
Ÿ Closed-loop water systems: Recycle ~98% of factory water via reverse osmosis and multi-stagefiltration.
Ÿ Automation & “SPEED TO MARKET” smart factory tech: IoT sensors, real-time data
tracking, semi-auto sewing, robotic arms for spraying, 3D Mactec curing ovens, and datadrivenproductionschedulingviaSAIDigitaland Speed-to-Marketplatform.
2.ExpansionPlansinVietnam&USA
Vietnam:
Ÿ SAITEX is ramping up the mill's closedloop system to achieve full carbon neutrality by 2030
•Mactec ovens and IoT/robotics systems forsprayinganddistressing .
PLANTREPORT
We reduce our own indigo with the SmartTMIndigo System to produce hydrosulfite-free indigo dye baths that only use indigo pigment, caustic soda, water and electricity. That system utilizes an electrochemical dye bath preparation that emits 90% less CO2, consumes 70% less energy and 30% less water where the only waste productisoxygen.
Besidesthatweareusingropedyeingtechnology TM from Karl Mayer that produces with just eight dyeing units deep, pure shades with a dye applicationofupto5.5%oftheyarnweight.
Thankstotheshortwetzone,upto25%lessbath volume is required compared to conventional counterparts.
Overall, the machine uses less energy, less water and fewer chemicals. Water consumption can be reduced by roughly 30%. Our main target is to produce sustainable, unique and laser friendly indigo shades. Especially the laser-friendliness plays a major role in the concept of our circular integration as it allows our garment factory to create wash effects with less water and less chemicals used and ultimately will lead us to create vintage effects without any water or chemicalsused.
Inourdyeingfacilitiesweusenofreshwaterbut recycled water in cooperation with the industrial park which is possible through the reverse osmosis and ultrafiltration technology that we haveinvestedinto.
All the fibers which we use are only sustainably produced and use sustainably processablefibers
Ÿ OrganicCotton(GOTScertified)
Ÿ RegenerativeCotton
Ÿ LycraEcomadeandLycra162R(Lycra)
Ÿ T400Ecomade(Lycra)
Ÿ RoicaV550(AsahiKasei)
Ÿ LubrizolX4J-zol(Lubrizol)
Ÿ RefibraTrueCo2Zero(Lenzing)
Ÿ RecycledCotton(Purfi)
Ÿ RecycledPolyester-GreenGold(Reliance)
Ÿ Hemp(PandaBiotech,Canvaloop,Marmara)
5.Sustainable Wastewater Treatment & Energy Optimization
Ÿ Zero discharge system: 98% recycled + 2% evaporated; no wastewater released into the environment .
Ÿ Multi-stage filtration & RO: Water is cleanedtodrinkablestandards .
Ÿ Sludge-to-bricks initiative: Facility sludge is repurposed into building bricks for socialhousing .
Ÿ Energy efficiency:Solarpower:3–4 MW of panels in Vietnam, covering ~25%+ of power needs; saves ~5.3 M kWh/year and cuts CO₂ emissions~80% .
Ÿ Heat recapture & air drying: Reduces dependenceonelectricdryers .