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Industry Overview
Enzymes have been used in textile processing and finishing for many years, particularly for removing starch-based sizing. Over the past two decades, their application has expanded across a wide range of textile processes. Denim, one of the world's most popular clothing materials, has traditionally been stonewashed with pumice stones to create a faded, distressed appearance. Although effective, conventional stonewashing can damage machinery, obstruct drainage systems, leave residues, increase water pollution, and cause excessive abrasion of hems, seams, and waistbands.
Bio-stoning provides an eco-friendly alternative by using cellulolytic enzymes, particularly cellulases, to assist in removing indigo from denim surfaces during washing. The process can produce the desired worn or stonewashed appearance without pumice stones and under comparatively mild processing conditions. It can also reduce mechanical damage, sediment in wastewater, and the space occupied by stones in laundry equipment, potentially improving productivity and denim quality.
Denim is commonly woven from cotton in a warp-face twill construction, with blue warp yarns and white weft yarns. Indigo, sometimes combined with sulphur dye, is widely used because it produces attractive fading characteristics without substantially staining the white weft yarns. Cellulase-based denim washing has therefore become an important biotechnology application in textile finishing. The report also covers enzyme properties, stone-free enzyme formulations, raw materials, manufacturing processes, plant layout, safety, utilities, location factors, project implementation, and the textile enzyme and denim industries.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 3 Ton/Day |
| Land & Building (700 sq.mt.) | Rs. 1.02 Cr |
| Plant & Machinery | Rs. 22 Lac |
| Working Capital for 2 Months | Rs. 2.59 Cr |
| Total Capital Investment | Rs. 3.90 Cr |
| Rate of Return | 49% |
| Break Even Point | 38% |
Content Index
- INTRODUCTION
- PROPERTIES & CHARACTERISTICS OF ENZYME
- STONE ENZYMES WASH
- IN STONE WASH, THE FOLLOWING POINTS SHOULD BE CAREFULLY CHECKED:
- A) SIZE OF THE STONES:
- B) GARMENT-STONE RATIO:
- YOU MAY ALSO LIKE: STONE WASHING PROCESS OF DENIM FABRIC
- C) WASHING TIME:
- D) QUANTITY OF THE BLEACH:
- OBJECTS OF STONE ENZYME WASH:
- PROCESS OF STONE ENZYME WASH:
- FIRST STEP: PRETREATMENT/DESIZING
- SECOND STEP: HOT WASH
- THIRD STEP: ENZYME STONE WASHING
- YOU MAY ALSO LIKE: STONE WASH PROCESS OF GARMENT STONEWASH WITH CHLORINE
- FOURTH STEP: BLEACHING
- FIFTH STEP: NEUTRAL WASH
- SIXTH STEP: SOFT WASH
- SEVENTH STEP: HYDRO-EXTRACTOR MACHINE
- EIGHTH STEP: DRYING MACHINE
- B.I.S. SPECIFICATION
- OVERVIEW OF TEXTILE AND GARMENT INDUSTRY IN BANGLADESH
- CURRENT SCENARIO OF DENIM MARKET OF BANGLADESH
- TOP FOREIGN DENIM BUYER OF BANGLADESH
- SWOT ANALYSIS OF DENIM SECTOR OF BANGLADESH
- STRENGTH OF BANGLADESH DENIM INDUSTRY
- WEAKNESS OF BANGLADESH DENIM INDUSTRY
- OPPORTUNITIES OF BANGLADESH DENIM INDUSTRY:
- THREATS OF BANGLADESH DENIM INDUSTRY
- TEXTILE ENZYMES MARKET
- GLOBAL TEXTILE ENZYMES MARKET SEGMENTATION ANALYSIS
- TEXTILE ENZYMES MARKET, BY TYPE
- TEXTILE ENZYMES MARKET, BY APPLICATION
- TEXTILE ENZYMES MARKET, BY GEOGRAPHY
- KEY PLAYERS
- PRESENT MANUFACTURE OF STONE FREE ENZYMES
- INDUSTRIAL APPLICATIONS OF ENZYMES IN TEXTILES
- TEXTILES PROCESSING
- STONEWASHED JEANS WITHOUT STONES
- YARN TREATMENT
- RAW MATERIALS DETAILS
- PROTEOLYTIC ENZYMES
- ANIONIC SURFACTANTS
- SODIUM LAURYL SULPHATE
- OTHERS IN THIS GROUP ARE:-
- NON-IONIC SURFACTANT
- SESQUESTRANT
- SODIUM SESQUISILICATE
- ENZYMES CLASSIFICATION FOR TEXTILE PROCESSING
- HYDROLASES
- AMYLASES
- PECTINASES
- PECTIN ESTERASES:
- POLYGALACTURONASES:
- PECTIN LYASES:
- PROTEASES
- LIPASES/ESTERASES
- OXIDOREDUCTASES
- PEROXIDASE/GLUCOSE OXIDASE
- FORMULATION OF POWDER ENZYMES [STONE FREE]
- MANUFACTURING PROCESS OF POWDER ENZYMES (STONE FREE)
- PROCESS FLOW DIAGRAM
- FORMULATION OF ENZYMES USED FOR DENIM CLOTH AND GARMENT WASHING (POWDER FORM)
- PROCESS FLOW DIAGRAM
- PRINCIPLES OF PLANT LAYOUT
- STORAGE LAYOUT:
- EQUIPMENT LAYOUT:
- SAFETY:
- PLANT EXPANSION:
- FLOOR SPACE:
- UTILITIES SERVICING:
- BUILDING:
- MATERIAL-HANDLING EQUIPMENT:
- RAILROADS AND ROADS:
- MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
- PLANT LOCATION FACTORS
- PRIMARY FACTORS
- 1. RAW-MATERIAL SUPPLY:
- 2. MARKETS:
- 3. POWER AND FUEL SUPPLY:
- 4. WATER SUPPLY:
- 5. CLIMATE:
- SPECIFIC FACTORS
- 6. TRANSPORTATION:
- A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
- 7. WASTE DISPOSAL:
- 8. LABOR:
- 9. REGULATORY LAWS:
- 10. TAXES:
- 11. SITE CHARACTERISTICS:
- 12. COMMUNITY FACTORS:
- 13. VULNERABILITY TO WARTIME ATTACK:
- 14. FLOOD AND FIRE CONTROL:
- EXPLANATION OF TERMS USED IN THE PROJECT REPORT
- 1. DEPRECIATION:
- 2. FIXED ASSETS:
- 3. WORKING CAPITAL:
- 4. BREAK-EVEN POINT:
- 5. OTHER FIXED EXPENSES:
- 6. MARGIN MONEY:
- 7. TOTAL LOAD:
- 8. LAND AREA/MAN POWER RATIO:
- PROJECT IMPLEMENTATION SCHEDULES
- INTRODUCTION
- PROJECT HANDLING
- PROJECT SCHEDULING
- PROJECT CONSTRUCTION SCHEDULE
- TIME SCHEDULE
- ADDRESSES OF RAW MATERIAL SUPPLIERS
- SUPPLIERS OF ALKALINE PROTEASES
- SUPPLIERS OF ACETAMIDE
- SUPPLIERS OF SODIUM LAURYL SULPHATE
- SUPPLIERS OF SEQUESTRANT
- SUPPLIERS OF SODIUM SILICATE
- SUPPLIERS OF SODIUM SULPHATE
- ADDRESSES OF PLANT AND MACHINERY
- SUPPLIERS OF PULVERISER
- SUPPLIERS OF MIXERS
- SUPPLIERS OF STORAGE TANKS
- SUPPLIERS OF VIBRATORY SCREEN
- RAW MATERIALS CALCULATION/MONTH
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Bio-stoning is an enzyme-based denim washing process that creates a worn or stonewashed appearance without relying on pumice stones.
In this process, cellulolytic enzymes such as cellulases assist in removing indigo from the surface of denim during washing. Mechanical action in washing equipment works together with the enzyme treatment to produce the desired faded and distressed appearance. Compared with conventional stonewashing, bio-stoning can reduce machinery damage, stone residue, drainage blockage, and excessive abrasion of garment components while supporting efficient denim finishing.
Cellulase enzymes are used because they help create the faded and abraded appearance desired in denim finishing.
Cellulases act on cotton-based denim surfaces and can enhance the worn-out effect when combined with suitable mechanical action in washing equipment. The report notes that cellulases with strong EG activity are preferred for achieving denim wear effects. Their use allows processing under comparatively mild conditions and reduces dependence on pumice stones and harsh chemical agents, while also helping to limit garment and machinery damage.
Traditional pumice-stone washing can cause equipment damage, drainage problems, fabric abrasion, and residue-related waste.
The physical abrasion produced by pumice stones can damage machine parts and can excessively wear sensitive garment areas such as hems, seams, and waistbands. Stone residues can also obstruct drainage systems and create difficulties during wastewater handling. In addition, the process can contribute to water pollution. These limitations are among the principal reasons enzyme-based stone-free processing has been developed as an alternative approach to denim finishing.
The reported process consists of pretreatment or desizing, hot washing, enzyme stone washing, bleaching, neutral washing, soft washing, hydro-extraction, and drying.
These stages prepare the denim, apply the enzyme treatment, develop the required appearance, and subsequently remove or neutralize process chemicals before finishing. Actual operating conditions such as washing time, enzyme dosage, temperature, mechanical action, and bleaching conditions need to be selected according to the fabric, garment construction, enzyme formulation, equipment, and required finish.
Enzyme washing can improve denim processing by reducing dependence on pumice stones while producing controlled worn and faded effects.
The stone-free approach can reduce abrasion-related damage to machinery and garments and can decrease solid sediment entering wastewater systems. Removing stones from washing equipment can also provide more usable machine capacity. The report further identifies potential benefits in productivity, denim quality, and operating cost compared with conventional stonewashing, although actual results depend on process conditions, equipment, enzyme formulation, and production requirements.
The report identifies several raw-material categories, including proteolytic enzymes, surfactants, sequestrants, and silicate-based materials.
Specific materials listed include alkaline proteases, sodium lauryl sulphate, non-ionic surfactants, sodium sesquisilicate, sodium silicate, sodium sulphate, and acetamide. The report also discusses enzyme classes relevant to textile processing, including hydrolases, amylases, pectinases, proteases, lipases or esterases, and oxidoreductases. The exact formulation depends on the intended textile application and required processing performance.
Enzyme manufacturing plant planning should consider raw-material supply, markets, utilities, transportation, waste disposal, labour, regulations, site characteristics, and safety.
The report also addresses plant layout, storage and equipment layout, building requirements, material handling, roads, utilities servicing, floor space, expansion provisions, and fire and flood control. Location planning includes primary factors such as raw materials, markets, power and fuel, water, and climate, along with specific factors including transportation, waste disposal, labour, regulatory laws, taxes, community considerations, and site vulnerability.
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