Welcome NoStone®, the innovative, more sustainable process for denim manufacturing
A big collaboration between an Italian company and a brand with a strong Italian heritage is about to change the world of fashion: from one hand Tonello, the reference point for the garment finishing industry since 1981; from the other one Levi’s Strauss – which doesn’t need any introduction, that worked together in the creation of NoStone®.
It was on January 2013 when Tonello Research Center and the denim brand started collaborating and rethinking how how to achieve a traditional stone-wash with XXI century innovation to reduce costs and environmental impact. The result is this new washing system already implemented in real production situations and applied in all Tonello machines.
A real advance in denim manufacturing thought to overcome economic, mechanical and environmental limitations of existing stone-wash processes. The idea is quite simple: creating a new system that will reduce water consumption, production costs, carbon footprint, emissions, processing time and manual labor. Indeed, NoStone® eliminates the dust and sludge generated from stones (which means no more stones and related mining, transport and storing), doesn’t damage the machine as pumice stones do, and creates desired finish effects of stone-wash in both sampling and production machines. Moreover, it maintains the same load capacity while the lining can easily be removed – so the machine can also run normal washing and dyeing processes.
So, instead of the pumice, what does this new system use to replace the abrasive stone? The big new is a stainless-steel abrasive drum, fastened to the washing machine, that can create a variety of finishes through flexible abrasion adjustments to create the look and styles varieties consumers love.
“We challenged our team with the dream of a viable, mechanical alternative to pumice stones. Tonello created multiple rounds of machine prototypes which were tested in our production environment. The results have been very positive and we anticipate a scalable, cost-effective and sustainable process in the very near future. This will be a win for our two companies, but also the industry as a whole. And perhaps, most importantly, the environment” said Bart Sights, Senior Director of Technical Innovation, Levi Strauss & Co.