Raymond UCO Denim Pvt Lts. in India explains why it has chosen the STeP by OEKO-TEX® certification.

What are your philosophy and strategy for sustainable production?

We believe in the controlled optimisation of our resources for sustainable production.

What are your reasons for becoming STeP by OEKO-TEX® certified?

We have been following sustainable practices for many years, but to get them endorsed by a universally accepted certifying body, we have opted for the STeP by OEKO-TEX® certification.

How does the OEKO-TEX® certification scheme help you in communicating your success in sustainable production with your stakeholders and can it help in communicating your performance and target setting with your buyers?

We are already using RSL free chemicals, maintaining a 100% biological ZLD ETP plant active, providing a safe production facility and practicing social responsibility. However, we still felt the need to communicate to our customers our sustainable initiatives in a better way. Since OEKO-TEX® is a well-known and universally accepted eco-label for textile / apparel products, we thought this is the right platform for us. After achieving the STeP certification Level 3, our competitive edge on sustainability can be communicated in an easier way with our stakeholders and brand partners.

What innovative technologies are installed in your facilities to enhance efficiency, save resources, reduce consumption, encourage circularity, and reduce costs?

• Sustainable production approach by using PCW and PIW for manufacturing of denim fabric
• ECO Green and Coolmax® uses recycled polyester fibre thereby reducing the use of cotton
• Use of BCI and organic cotton over conventional cotton
• Cadira® and dyeing with less water reduces salt generation significantly and water consumption by more than 70% in the dyeing effluent
• Waste recovery plant for recovery & reuse of cotton waste generated in the blow room sectio
• Zero Liquid Discharge biological ETP with advanced effluent quality monitoring system and sludge mineralisation concept which helps to significantly reduce sludge generation
• A sludge dryer has been installed for 100 % recycling of biological ETP sludge in-house
• Biogas generation based on canteen food waste which helps fulfil fuel requirement of cooking in the canteen
• Caustic Recovery Plant – recovery of caustic and water from weak caustic lye, generated from mercer operation
• Industry 4.0 automation is done in various process machines, looms with latest drive, control and communication system with field instruments to achieve best utilities figures
• Reduced the GHG emission significantly and set a target of reducing it by 2% every year
• Target: 10% reduction in water used by process machine by 2025
• Target: 1.5% reduction in electrical energy consumption every year
• Reduced the specific water consumption in process by using innovative techniques such as:
  • a) using of mist evaporation in humidification plant
  • b) Using of 4 stage filtration and MEE plant in ETP
  • c) Recovery of indirect cooling water from process machine etc

Please cite some examples on the best practices being adopted in your facilities for better chemical management.

Input Control

• Monitoring RSL compliance on a regular basis
• Scrutinizing all the incoming chemicals on the basis of STeP by OEKO-TEX® RSL / MRSL guidelines
• Sourcing only ZDHC gateway registered chemicals, and using Level 3 chemicals only
• Seeking self-declarations for RSL / MRSL compliance from the chemical vendors and confirming with random testing from the authorised third party

Fabric Monitoring

• Having STANDARD 100 by OEKO-TEX® certification with Product Class 1 category (as per Annex 6)
• Random testing through the authorised third party as per buyers’ protocol

Control through wastewater testing

• Testing waste water and sludge twice a year through ZDHC approved laboratories

Failure analysis and implementation of CAP with robust Chemical Management System procedures documented and approved by the top management.

What are the major challenges in getting your facilities STeP by OEKO-TEX® certified? And how did you overcome these?

Aligning suppliers to comply with the STeP criteria and Code of Conduct. The suppliers were persuaded by us as well as by the external stakeholders. Looking into the long term sustainability in ESG terms of the entire supply chain, they have agreed to follow STeP requirements.

Do the management team see the positive changes after implementing the STeP by OEKO-TEX® system in your facilities in terms of people, management, productivity, product quality, environmental impact, brand image?

We at Raymond UCO Denim have adopted sustainability initia-tives right from the inception but now after the recognition by STeP by OEKO-TEX®, those approaches have been uniquely identified and recognised by our customers.

How does the management comment on STeP by OEKO-TEX® compared to other industry assessment tools?

STeP by OEKO-TEX® is a widely known and accepted as compared to other eco-labels. It has boosted our brand image.

What are the next steps for your sustainable production journey, after getting your first facilities STeP by OEKO-TEX® certified in terms of the 6 STeP modules?

After attaining STeP Level 3, we aim to first maintain it and then push for incremental elevation in the due course of time.

How do you comment on your experience working with TESTEX to obtain STeP certification?

It was a great learning for us working with TESTEX. In chemical, environmental, social and safety aspects the institute has passed on a great deal of knowledge to us. It has instilled us with the driving force to remain differentiated in this ever changing global market.

What is your CEO’s comment on successfully becoming STeP certified?

We are happy that our efforts on the sustainability front are recognised by a renowned certifying body like OEKO-TEX®. We strongly believe that STeP by OEKO-TEX® will help us project our production facility as a symbol of trust on the ESG sustainability to our global brand partners.

Do you plan on introducing the MADE IN GREEN by OEKO-TEX® label?

Since we are a denim fabric manufacturer, STeP by OEKO-TEX® enables our garment vendors to acquire the MADE IN GREEN by OEKO-TEX® label.