Sustainability
Whether through our reduction of water, energy and material, or through the use of technology, sustainability
WATER
WASTE
ENERGY
MATERIALS
TECHNOLOGY
WATER
Our process uses:
1.5L to 3L of fresh water per garment in finishing
Traditional denim
manufacturing uses :
85L to 100L of fresh water per garment in finishing
WE SAVE 235,000,000 LITERS OF WATER PER YEAR
100% recycled water after evaporation
We conserve this much because we process and treat 100% of our post-laundry wastewater before it is
pumped back into our system. Once it enters the laundry again, the treated water is mixed with 1.5 to 3
litres of fresh water for every 85-100 litres of recycled water.
235 million liters saved
is equal to the annual consumption of
230 thousand people.
WASTE
Our Frontline water treatment plant is monitored and
audited by 3rd party officials to ensure that every drop
is free of post processing waste.
The post procesed water waste (sludge) that is removed
is mixed with conventional cement, donated and made
into building blocks used in local civic construction projects.
At the end of the Frontline process there is zero harmful
discharge into the water system.
ENERGY MATTERS
Our ambient hang-dry conveyor system elimintates 90%
of the normal power consuption needed to power conventional
dryers at most laundries. Because of this power savings
the greenhouse gas emissions from drying are also
reduced by 90%.
This is equal to the savings of 400 thousand kwh of power
which can power 150 electric cars for an entire year.
ENERGY MATTERS
Our ambient hang-dry conveyor system elimintates 90%
of the normal power consuption needed to power conventional
dryers at most laundries. Because of this power savings
the greenhouse gas emissions from drying are also
reduced by 90%.
This is equal to the savings of 400 thousand kwh of power
which can power 150 electric cars for an entire year.
100% OF PRODUCTION IS AIR DRIED USING 90% LESS POWER
90% REDUCED CO2 EMMISIONS
400,000 KWH OF POWER SAVED A YEAR
SOLAR
By the end of Q1 2021 our long awaited solar power installation
will be complete. Our energy savings for 2021 will be
5.5million kwh, which could power 2400+ electric cars for an
entire year.
Our conversion to renewable energy will reduce total greenhouse
gas emissions and environmental impact to almost
zero during the generation of our solar power.
MATERIALS
It all starts with fabric and our in-house Frontline library of sustainable fabrics is constantly being updated with
the latest and greatest developments from around the world. We are your one-stop-shop for fabric R&D.
Our library consists of BCI certified recycled
and organic cottons, recycled poly and other
blends with cellulose (natural) fibres as well
as fabrics dyed using zero water and
sustainable dyes.
RECYCLED AND ORGANIC COTTON
We have experienced dye technicians that
have developed and perfected the use of
ZDHC approved sustainable and botanical
dyes for your overdye needs on pfd or
denim.
Our newly planted boutique indigo farm
has been set up to supply our real 100%
natural indigo overdye process and will be
available by the end of 2021 to use on your
pfd developments
INDIGO FARM / BOTANICAL DYES
This is a revolutionary new technology,
which conumes ZERO WATER in the
piece-dye process. Please enquire.
ZERO WATER DYE
TECHNOLOGY
We have always invested in latest technology and continue to research new ways to reduce environmental and worker impact.
ALL IN ONE MACHINE
Our Tonello All-In-One eco-free
2 does exactly what it says. It is
an all-in-one solution replacing
multiple wet-processees
normally done using several
machines and extensive labour.
These machines can reduce
water consumption and waste by
up to 95% and reduce chemical
waste and consumption by 50%
as chemicals are jet-sprayed
within the machine drum versus
in open air. This machine eliminates
potential worker exposure
to chemicals by 100%.
STEAM RECYCLE
Our steam recycling heat
exchanger saves 40% of the
outgoing energy normally
wasted and discharged into
the air.
JEANOLOGIA LASER
The Laser machine eliminates
Chemical PP (potassium
permanganate) creating
authentic whisker and dry
process wear-patterns
normally created using
manual labour and harmful
potassium. We can also design
and execute custom print
artworks.
TONELLO CORE MACHINE
Our Tonello Core machine is
used to apply sustainable
chemicals like resin, dyes etc
to garments within the closed
loop system to create uniform
or modular fashion dye
effects, again reducing worker
exposure and chemical usage.
1. Open up the camera app / Camera
2. Position your phone so the QR code
appears in the digital viewfinder
3. Launch the code
4. You will see the EIM chart of the
sustainable sample
FRONTLINE ECO-QR CODE
Each garment we produce can be assigned a unique Frontline ECO-QR code that is printed and attached directly to the garment. Once scanned with any smart phone, this code communicates both the actual EIM score of the product and the projected EIM score of the same wash done using non-sustainable methods. This will show how impactful the savings on every single jean we produce is.
1. Open up the camera app / Camera
2. Position your phone so the QR code
appears in the digital viewfinder
3. Launch the code
4. You will see the EIM chart of the
sustainable sample
FRONTLINE ECO-QR CODE
Each garment we produce can be assigned a unique Frontline ECO-QR code that is printed and attached directly to the garment. Once scanned with any smart phone, this code communicates both the actual EIM score of the product and the projected EIM score of the same wash done using non-sustainable methods. This will show how impactful the savings on every single jean we produce is.
WHAT IS THE EIM SCORE ?
EIM is a simple tool that allows our laundry technicians to measure
and assess the environmental impact of our finishing process. The
tool measures the impact on water use, chemical use, energy use
and worker exposure. The lower the score the better.
score score score
67-100 34-66 0-33
HIGH MEDIUM LOW
impact impact impact
COLLABORATIONS AND PARTNERSHIPS FOR A CIRCULAR FUTURE
Redress
Initiated partnership with Redress.
Mid – 2019
Mentor workshop tour of our sustainable
laundry for 2020 finalists of the internationally
acclaimed Redress design award circular
design contest. Mid – 2020
Unspun
Initiated partnership with Unspun denim.
Late – 2019
Frontline nominated as sustainable laundry
partner for all Unspun denim. Mid – 2020
The Jeans Redesign
Joined the Ellen MacArthur Foundation’s
The Jeans Redesign program. Late – 2019
Continue to develop our work with clients on
lifecycle solutions in design towards a more
circular economy for denim.
SOLUTIONS THROUGH EVOLUTION TIMELINE
