The main objective of this project was the research and development of new manufacturing processes for sustainable and functionalized denim fabrics for the textile-fashion sector, resulting in a new concept of coloration within the denim industry.
As a result, four types of denim fabrics were developed, differentiated according to their end-use applications (1: bags; 2: footwear; 3: jeans and jackets; and 4: shirts and lighter garments), achieving a wide range of color shades. The main critical aspect of this development was related to the coloration process, as it represents both the core innovation of the project and the most significant stage in achieving the desired denim aesthetics. The application of color through coating using a new dyeing medium (primarily composed of natural pigments and recycled resins) was previously unknown at an industrial level.

As a result, the project enabled the successful development of four new sustainable denim production methods, generating a new concept of denim coloration with a low carbon footprint and reduced water consumption, while promoting circular economy principles within the textile sector. Thanks to this innovation, the company has developed its own range of sustainable and functionalized denim fabrics and established four new coloration methods for denim textiles.

To achieve the desired final product, ONDYTEC initiated the work by selecting sustainable base fabrics and defining the optimal preparation methods. Subsequently, natural pigments and auxiliary products were selected, determining the optimal proportions to ensure compatibility. The four sustainable coloration processes were then studied and defined (knife coating, spray application, air knife coating, and foam application), followed by finishing processes (laser treatment and sanding), concluding with the definition of functional finishes according to the specific textile application.

It is important to highlight that, at each stage of the process, the most efficient conditions were selected both at laboratory and industrial scale, ensuring the feasibility of a sustainable denim manufacturing process.

As a result, ONDYTEC successfully completed the project, developing four new methods for producing sustainable denim fabrics, enabling the creation of four different fabric types available in five color variations, suitable for various subsectors of the fashion industry. This contributes to transforming the denim sector by introducing a new concept of denim production with a low carbon and water footprint, while fostering circular economy principles within the textile industry.