Mr. Kasper joined Dyecoo in Oct. 2015 as Managing Director for Dyecoo Asia and is based in Taipei. Prior to joining Dyecoo, he worked for 3.5 years as a diplomat in the field of the Science & Technology. Before coming to Taiwan he worked at Xennia Technology in the UK, as business developer for advanced digital printing applications and at Royal TenCate, in the Netherlands, where he worked as a program manager for low liquor and low energy dyeing and finishing technologies based on digital printing.
Mr. Kasper, is a Dutch national and holds a B.Sc. in Chemical Engineering and a M.Sc. in Innovation Management from Utrecht University in the Netherlands.
Speaking with Publisher & Correspondent of TAI – Mr. J.B. Soma, Mr. Kasper Nossent, tells us about Waterless Dyeing – a great environmental blessings in today’s time.
Q. Kasper Nossent, please give us a brief background of DyeCoo Textile Systems.
A. DyeCoo is the first and so far only company in the world that provides a full industrial and commercial viable technology to dye 100% polyester without water and process chemicals, by using super critical CO2 as the dyeing medium. DyeCoo’s technology is developed in the Netherlands at the University of Delft in collaboration with the Dutch company Fyecon. A first commercial prototype has been installed in 2010 at Tong Siang (Yeh Group) in Thailand and the machine was fully commercialized in 2012 with machine installations in Thailand and Taiwan and currently we are growing our presence in Asia.
Q. It is great compliments to for being the world’s first water-free and process chemical-free textile dyeing solution provider. What was the inspiration and motivational factor in developing waterless dyeing process by DyeCoo?
A. It started with scientific curiosity that quickly developed into a motivation to do something radically different with a big sustainable impact. Where the whole textile industry always focused on using less water and less chemicals, DyeCoo focused on not using any water or chemicals at all with a unique and complete disruptive technology.
Q. What where challenges & Struggles you have faced in developing this?
A. Being the first in the market means you have to discover everything yourself, the technical challenges when upscaling the technology, the economics and market drivers. There are no standards and no examples to work with, but over the past years DyeCoo managed to fully commercialize the technology and to make it technical viable and reliable for dyeing 100% polyester knitted and woven fabrics. In December 2016 we launched the DyeOx4.0, the fourth generation of the machine, which shows a constant drive to improve and innovate.
Q. What are the product benefits in using DyeCoo technology?
A. On the first place off course a sustainable product with a lower production cost. But the technology also brings other benefits such as very vibrant colours, especially for fluorescent colours, high fastness properties, easy colour correction and very high batch to batch colour consistency.
Q. What are the environmental impact & Key statistics of this technology?
A. The main sustainable impact is off course zero water, zero waste water and zero process chemicals. Because the DyeCoo dyeing technology is a zero liquor discharge technology, it fits very well in ZLD factory designs. Besides the water and chemical savings, the technology is also more energy efficient compared to water based dyeing technologies.
Q. How did you commercialized this technology with a sustainable position in the global market?
A. For a sustainable technology to be commercial attractive it needs to be more than only sustainable, DyeCoo focusses on providing a technology that also saves significant production cost, making it more attractive for businesses to invest. Besides a strong commercial proposition, having strong partnerships is just as important. From the start we closely collaborated with our dye stuff partner Colourtex to ensure the availability of CO2 dyes for polyester. And with Adidas and our partner and shareholder NIKE we were able to introduce the first machines into the market for sports apparel. Now we see growth towards other fields of application such as footwear, outdoor, upholstery the automotive industry and the retail sector.
Q. Who are the key customers globally and how is the Indian market?
A. Our first customer was Tong Siang (Yeh Group) in Thailand and at the moment DyeCoo has 5 customers and 8 machines in operation in Thailand and Taiwan. Last June we sold our 9th machine to Far Eastern Textiles in Taiwan and we are working on expanding towards Vietnam and also India.
India provides a great opportunity for DyeCoo, in terms of stricter legislation, a growing pressure on clean water usage and large industry players in polyester that want to lead by example, such as Reliance, Arvind, Sangam and Raymond. We therefore look forward to expand further into India.
Q. Can you tell us more about the DyeOx4.0, the latest CO2 dyeing machine?
A. DyeCoo launched the DyeOx4.0, the latest version of our machines, which was launched in December and we recently installed 2 units in Taiwan. The machine is suitable or knitted fabrics and woven fabrics and the output of a DyeCoo machine is on average 1mln kg per year (depending on shade and fabric dimensions), with an average of 24 dye batches a day and a maximum load of 200kg per batch and a maximum fabric width of 200cm.
Q. Can you explain the economic and the operational costs compare to present available technology in operation?
A. CO2 dyeing is a new and high tech technology, which requires larger capital investments, but provides significant lower operational cost compared to traditional water dyeing. In some case studies the operational cost can be 40% lower than water dyeing.
Q. What are the latest R&D innovations of your company?
A. DyeCoo constantly works on new applications to increase the scope of the technology. At the moment we work on a polyester staple fiber dyeing application for the Indian market and together with our long time dye stuff partner Colourtex we work on Nylon dyeing, which we hope to launch in 2018.
In Taiwan we work with one of our customers to develop a polyester/elastane dyeing process for CO2.
Q. What will be the capital investment and pay-back period?
A. The capital investment for one DyeCoo machine, with an annual output of around 1mln kg per year is quoted in the ball park of EURO 2.4 mln.
The payback periods depends per customer, but we aim to focus on payback periods of less than 5 years. It has to be noted that an investment in CO2 dyeing is also an investment in a sustainable long term future for your business and it ensures that you can still operate a dye house in 10 years from now with more and more stricter legislation on water and waste water or a mandatory ZLD factory, which require significant capital investments or in the worst case, closure if one does not comply with the legislation.
Q. Who have installed this who are in pipeline to decide?
A. At the moment our machines are running at Tong Siang in Thailand and in Taiwan at Far Eastern Textiles, Formosa Taffeta, ECLAT and LiCheng. We are working to expand our customer base in Taiwan and towards Vietnam with new customers that want to build CO2 dye houses.
In India we are currently working with the industry leaders and hope to develop soon the first flagship demonstrator for CO2 dyeing in India.
Q. How do you see your market segment growing in the next 5-10 years both locally and internationally?
A. For the coming 10 years we expect a significant growth in the market for CO2 dyeing, not only in Asia but also in Europe and North America, the first to adopt the technology will be innovators and those that want to lead by example, then the technology will become more mainstream and will flow to the rest of the market. Also the introduction of new CO2 applications and an increasing pressure on sustainability from brands, society and legislation will boost the growth.
Published on: 06/09/2017
DISCLAIMER: All views and opinions expressed in this column are solely of the interviewee, and they do not reflect in any way the opinion of The Textile Association (India).