Case Details
Executive Summary
HL Garment Washing Factory, a crucial denim processor for China's top-tier brands, underwent a comprehensive technological transformation with the help of Liying's integrated solutions. This project achieved a 58% reduction in wastewater discharge, a 32% labor savings, production that met ISO certification standards, and simultaneously set a new benchmark for sustainable manufacturing.
Industry Background
China's denim washing industry is confronted with severe challenges:
- 40% of factories utilize decade-old equipment (China Textile Engineering Association, 2024).
- The average chemical oxygen demand (COD) level in wastewater ranges from 2,500 to 3,500 mg/L, exceeding the GB4287-2012 standards.
- Labor costs have increased by 28% year-on-year since 2020 (National Bureau of Statistics).
Challenges Faced by HL Before Transformation
Technical Obsolescence
- 12 traditional horizontal washing machines, consuming 85 cubic meters of water per ton of denim.
- Inconsistent batch processing, resulting in a 15% rework rate.
Operational Limitations
- Three-shift production requiring 45 operators.
- An annual employee turnover rate of 23% due to ergonomic issues.
Liying's Integrated Solution Framework
Phase 1: Process Reengineering
- Optimized workflow and implemented a U-shaped production cell layout, reducing material transportation distance by 42%.
Phase 2: Advanced Technology Integration
- Production Washing Machine with High-speed Spin-cycle: XRQ-350A,
- Large capacity Energy-saving Tiltable Dryer: HGZ-250
Phase 3: Sustainability Implementation
- Closed-loop water system with a water reuse rate of 75%.
- Biogas recovery from anaerobic treatment, meeting 30% of thermal energy needs.
- Achieved Class 1A discharge standards under GB4287-2012, enabling expansion in ecologically sensitive areas.
Economic Benefits
- Payback period: 2.8 years.
- Annual reduction in operating costs: RMB 2.3 million.
Human Capital Transformation
- Employees' skills were upgraded, enabling them to manage advanced control systems.
Market Differentiation
- Obtained premium pricing for "eco-certified denim" (with an 18% increase in profit margins) and acquired three new international clients.
Client Testimonial
"Liying's solutions have completely transformed our fundamental business model. Not only have we met compliance requirements, but we have also become a paragon of sustainable manufacturing. The integration of intelligent equipment has elevated our technical capabilities, enabling us to compete on a global scale."
— Mr. Zhang, Production Director
This case study demonstrates how technological modernization can simultaneously address environmental compliance issues, enhance economic viability, and improve working conditions. Liying's four-pillar approach (process optimization, advanced equipment, resource recovery, and digital integration) provides a replicable framework for industry transformation.
TKD Metadata (Markdown Format)
Title: Denim Washing Revolution: How Haili Factory Achieved a 58% Reduction in Wastewater Discharge and 32% Labor Savings
Keywords:
- Sustainable denim processing
- Textile wastewater treatment
- Industrial automation in the garment industry
- Energy-efficient laundry equipment
- ISO certification
Description: A detailed case study on Liying's technological transformation of Haili Washing Factory, achieving a 96.6% reduction in chemical oxygen demand (COD), a 47% increase in productivity, and production standardization certification through advanced denim processing solutions.
