SPECIAL TREATMENTS &LAUNDRY

Our laundry is specialized in working out fashion solutions for denim. The washing processes are carried out with modern and environmentally friendly technologies to achieve high-quality results while working as sustainably as possible. Our customers can choose from a wide range of treatments, such as laser and ozone bleaching, as well as eco-stone and enzyme washes.

Approximately 4000 liters of water is consumed with standard techniques for one denim trousers. The chemicals used in these washings cause permanent damage to the environment. Merkoteks is changing this situation with the new technologies it uses. With the new washing technologies we use in production, we have reduced our carbon footprint by using 70% less water, 50% less chemicals and 79% less energy.

As Merkotes, we work to reduce our carbon footprint in nature.Sustainability discourse has now become mandatory for every sector. Sustainable production is becoming a way of life, not a trend. The world is changing. Due to the global pandemic, manufacturers and leading brands are trying to adapt themselves to produce more sustainably.

HOW TO WASH DENIM

With the new washing technologies, we use in production, we have reduced our carbon footprint by using 70% less water, 50% less chemicals and 79% less energy.

LESS WATER

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LESS ENERGY

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LESS CHEMICAL

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sustainable materials ECO-STONE

With Eco-Stone we can replace the pumice stone and achieve a similar washing effect with a cleaner appearance. Unlike pumice, Eco-Stone can be used for more than 1000 washes without leaving any residue. Thus, Eco-Stone washings can save more than half of the usual amount of water.

The Denim can be washed in a single rinse cycle because Eco-Stone, unlike pumice stone, leaves no dust or mud residue on the Denim.

In addition, since there is no wear on the stones, no additional stone fillings are needed during washing. This shortens washing time, increases production capacity, and saves energy and water costs.

BLEACHING Ozone & Enzymes

The first step of denim treatment to decolorize indigo is bleaching. Depending on the amount, of bleach used in combination with the temperature and duration of the washing process, the degree of discoloration changes.

The chemicals commonly used in the denim industry for this purpose are sodium hypochlorite, calcium hypochlorite, hydrogen peroxide and potassium permanganate. The corrosive properties of these chemicals can damage machinery and fabric; moreover, despite protective measures, high exposure is harmful to workers.

Ozone is a powerful bleaching agent produced from oxygen. It works quickly and requires fewer rinses compared to other bleaching methods. In additional, at the end of the bleaching process, the remaining ozone is converted back into oxygen and water. This is much more environmentally and water friendly than the usual methods using other corrosive chemicals.

As another alternative, enzymes can be used during the bleaching process. Enzymes change the indigo dye by oxidation. Because of this only the dye and the appearance of the fabric are changed and not the quality, strength, and elasticity of the Denims.

Enzymes can also be used in combination with Eco-Stone to enhance the effect of the process.

Denim Dry Finishing LASER

The laser can be used, also to imitate hand sanding and sandblasting. Pre-programmed patterns can be used to achieve exactly the desired wear effects. Which eliminate manual sanding as well as the labor and physical risks of sandblasting.

Because laser systems are controlled by CAD/CAM technology, almost any distressed effect can be achieved quickly and consistently. These patterns can be precisely repeated or combined in an infinite number of new and unique worn designs.

Advantages of laser:

It consumes less water, energy and time.
Any complex design at any place can be created.
No hazardous, environment friendly and requires no chemical.
Accuracy, good quality production are high.
Less manpower required.

WASHING Techniques NO-STONE

Tonello grinding drums, made of stainless steel, are plates with different texture finenesses that can be attached to all Tonello machines. Since they are removable, the machines can still be used for other washing and dyeing processes.

The combination of the washing cycle with the different textures of the plates determines the degree of stonewash effect that should be achieved.

The NoStone process reduces the amount of used water and saves production costs, emissions, processing and manual labor time.

RESEARCH & DEVELOPMENT LABORATORY

Sweat fastness test
We evaluate the dyeing and discoloration resistance of the fabric to perspiration by performing acid and alkali fastness tests in our laboratory. By comparing our measured values with accredited laboratories, we verify the accuracy of our values and archive them.

Water Fastness Testing
Our denim is soaked in a certain amount of distilled water at normal ambient temperature together with a reference fabric. After a specified time, we observe if its color changes and whether it adds color to the accompanying fabric. The results are evaluated and archived accordingly.

Rubbing fastness test
Denim fabrics are subjected to our rub fastness test in dry and wet conditions. We evaluate the results according to the specified standard values.

pH Test
The pH test provides us with information about the chemical processes applied to the fabrics during production after washing. It also helps us to check whether we are carrying out the correct processes according to the fabrics. Our pH results take values between 4 and 7.5 which are within the range of acceptable levels of pH.