DBL - natural dyes, water efficiency and materials cycling | Knowledge Hub | Circle Economy Foundation
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DBL - natural dyes, water efficiency and materials cycling
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DBL group is among the largest knit garment manufacturers and exporters of Bangladesh. H&M, Walmart-George, Puma, Esprit and G-Star are among its major buyers.

Problem

Today, fashion accounts for up to 10% of global carbon dioxide output—more than international flights and shipping combined, according to the United Nations Environment Programme. The textile and apparel industry makes significant use of water, particularly in the fabric dyeing and finishing operations. The International Finance Corporation (IFC) of the World Bank Group reports that the Bangladesh textile and apparel industry currently consumes 1,500 billion liters of groundwater annually and discharges it as wastewater. 

Solution

DBL Group promotes several circular initiatives accross a variety of resources.

CHEMICAL MANAGEMENT

Since 2012 DBL is leading the apparel industry towards zero discharge of hazardous chemicals (ZDHC). The group has adopted ZDHC 2.0 for 100% of its inventory as of 2021. In this direction, the group turned to earth color dyeing, a new method for creating warm shades from natural colors. Seven dyes are recovered from the waste of non-edible agricultural and herbal industries.

RAW MATERIALS

DBL group spinning mills use different processes that reduce the consumption of cotton. Furthermore, recycled materials (eg. recycled textile, recycled polyester from PET bottles) are used instead of raw cotton. Indeed, DBL spinning mill, Matin Spinning Mills Ltd., is one of the most modern spinning mills in Bangladesh and it produces both Pre-Consumer and Post-Consumer Recycled yarn with GRS/ RCS certification.

WATER STEWARDSHIP

Compared to 2020, the group has reduced the use of ground water per garment by 19.42%. This was achieved by setting up a rainwater harvesting plant and backwash water recovery plant to use recycled water. These solutions have saved 100850 cubic meters of groundwater usage as of 2021.

Much of water consumption in textile manufacturing comes from dyeing. Up to 200 liters of water are required to dye one kilogram of fabric, but in 2010, DBL group only required 120, yet it was still not satisfied with its performance. To reduce this number, several water-saving opportunities were identified by DBL Group. Along with the existing practices, some of the implementations made by DBL include:

- Using efficient machineries which consume up to 50% less water than the average

- Using chemicals which require less water

- Repairing leaking taps and educating staff to turn off water after use

- Replacing water taps with aerator water taps

- Replacing single flush cisterns with dual flush

- Reusing hot water from boilers.

As a result of these practices, in 2016 DBL Group achieved water consumption of 55 liters per kilogram of fabric from 120 liters, thus saving 65 liters of water per kg of fabric.

LOCAL COMMUNITIES

In supporting local communities, DBL has built schools and provided computers to equipe local colleges. The group also offers recurring technical and vocational trainings for both employees and community inhabitants. DBL employees have access to further trainings every month ranging from first aid to waste handling and environment awarness. Finally, DBL group offers free medical treatments to all community members as part of recurring programs and free treatments all year round to workers and families.

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