Technoacque has developed an integrated treatment program to support companies in achieving their environmental goals and embracing an ecological transition, through the adoption of sustainable and eco-conscious practices.
The combination of a meticulous examination of the critical production factors with a specific focus on water, energy, and chemicals consumption and a holistic understanding of processes and modern treatment technologies, allows Technoacque to uncover solutions to enhance the quality of finished products, while promoting circularity, resource optimisation, and liquid waste minimisation.
Industrial laundries and dye-laundry companies in Italy operate on behalf of large users (hospitals, hotels, restaurants, industrial activities, etc.) and are among the activities with the highest consumption of water, energy and chemicals.
After the selection phase, the garments are sent to the washing process which generally includes a preparation phase, a dyeing phase and a finishing phase and then move on to drying, folding and packaging.
During the preparation phases, purging, sodating, mercerizing, desizing activities are carried out by immersing the fabrics in hot baths, at controlled temperature and pH, containing acidic and alkaline solutions and enzymes, in order to improve their shine, give them greater elasticity, tear resistance, hygroscopicity, etc., and prepare the garments for the next dyeing phase in which pH regulators, neutralizers, sequestrants, wetting agents, fixers, etc. are used to obtain brighter and more uniform colors.
In addition to the consumption of chemicals, the washing, dyeing and finishing phases require large amounts of heat to control the temperature inside the tanks and water for the preparation of the baths and the rinsing phases.
THE CASE OF AN INDUSTRIAL LAUNDRY
The integrated treatment program by Technoacque designed and implemented by Technoacque has helped an industrial laundry in the Naples metropolitan area to reduce its energy consumption and chemical usage in the washing phases, while improving product quality through the installation of two modules for primary water treatment and water recovery.
The system relies on membrane desalination technology via reverse osmosis, combined with micro-ultrafiltration systems, chemical-physical disinfection and water stabilization units.
The facility designed by Technoacque, designed to handle a treated flow rate of 500 m³/d, enabled the generation of ultra-low salinity water, with the right characteristics to serve as feed water for boilers, essential for steam production—a pivotal heat source in the process—as well as for preparing washing baths.
The exceptional purity of this water has reduced the need for boiler purging by approximately 90% and ensured continuous operations with a good tolerance for considerably higher concentration factors, always within regulatory limits.
The slight acidity of the osmosis water (pH of about 5.5 units) and the low alkalinity allowed a saving of about 90% in the use of acid formulations and stabilizers in the washing (preparation) phases, while the low presence of salts allowed a saving of about 10% of dyes, without compromising on the color rendering, and with a superior quality of the final garment both in terms of softness and elasticity of the fibers.
The waste from the desalination plant, after further treatment, was reutilised in full for the rinsing phases, maximising the use of primary water resources.
THE ADVANTAGES OF THE TECHNOACQUE PROGRAM
Technoacque’s integrated approach has yielded substantial benefits across energy, environmental, and economic fronts. Notably, a remarkable 25% reduction in fuel consumption for steam production was achieved, resulting in annual savings of approximately 40k € in fuel costs and an additional 25k € in chemical expenses.
Furthermore, the decreased demand for thermal energy has directly contributed to a significant reduction of about 180 tons of CO2 annual emissions, together with the reduction of NOx and particulate matter released in the atmosphere.
