Karl Mayer: Collaboration between IVL, DyeCoo...
Karl Mayer

Collaboration between IVL, DyeCoo and Stoll for sustainable mask

Source: Karl Mayer
Source: Karl Mayer

While face masks help greatly in mitigating the spread of the corona virus, they also contribute to environmental problems such as waste and pollution. Easy Mask is a collaborative initiative between Indorama Ventures Public Co. Ltd. (IVL), Bangkok/Thailand, process engineering company DyeCoo Textile Systems BV, Weesp/Netherlands and Stoll, Reutlingen/Germany a business unit of the Karl Mayer Group, Obertshausen/Germany. The aim is to produce a fashionable mask with a sustainable mind-set throughout the whole production process, starting from the yarn production and followed by the dyeing, design and production.

Deja, the sustainable performance yarn from IVL, is made from 100% post-consumer rPET bottles. It is 100% recyclable at the end of use and can be repeatedly re-processed without harmful emissions or discharges. The Deja recycled yarn is dyed with the innovative supercritical carbon dioxide textile dyeing technology by DyeCoo at CleanDye factory. The sc-CO2 dyeing machines can dye yarns or fabric rolls in a closed-loop process without using water and process chemicals. The sc-CO2 is 95% reclaimed in the machine, textile dyeing has less of an environmental impact compared to traditional dyeing technologies.

The mask is knitted on a Stoll CMS 530 HP B E 7.2 machine but can also be knitted on other types of Stoll machines. Easy Mask is 3D knitted and expands and collapses easily. It is simple to use and comfortable to wear. The design approach allows customization, on-demand production, and reduces production waste to below 1%. Integrated ventilation increases breathability. The seamless production method eliminates cut and sew and reduces waste material. Washing at 60°C makes repetitive use possible.

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