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/ Magazine / INTEGRATED WATER MANAGEMENT IN TEXTILE PROCESSES, ENVIRONMENTAL IMPACT AND ENERGY RECOVERY
by
MARZIO NAVA
In the textile industry, water management is becoming a strategic issue, not only environmentally, but also in terms of innovation, efficiency and competitiveness. Dyeing, washing and finishing processes are highly water-intensive and generate complex effluents. Addressing these challenges requires an approach that considers the entire water cycle, beyond conventional wastewater treatment. Reducing water consumption, recovering and reusing process water, and optimising wastewater treatment systems are key to minimising environmental impact and improving resource efficiency. Recovering heat from wastewater can further improve energy efficiency. The integrated management of water and energy is paving the way towards a more circular and sustainable industrial model, transforming environmental challenges into opportunities for technological development and growth. But what does it take to achieve the right balance in water management across textile care processes? To tackle this subject, we invited companies producing washing machinery, detergents and waste water treatment plants to share their experience
Balancing hygiene, textile care and sustainability is now one of the key challenges in both industrial and small laundry. For Walter Montanari, Managing Director of MONTEGA Srl, a company based in Misano Adriatico specialising in the development of professional laundry detergents, means managing water more efficiently - the indispensable resource for removing dirt and contaminants, yet increasingly precious. “Reducing the liters of water used for washing a kilogram of fabric does not simply mean cutting consumption,” explains Montanari. “We must preserve the mechanical action, the effectiveness of the detergents, and the ability to properly eliminate residues during the rinse phases. The issue is also energetic: less water to heat means lower energy consumption, costs and emissions. In addition, there is a need to minimise the impact of wastewater through optimised cycles, carefully calibrated dosing and filtration systems capable of capturing at least some of the microfibres, which are particularly significant in the case of synthetic fabrics. True innovation, therefore, does not consist in “washing with less water”, but in managing the entire process more effectively. Efficient equipment, high-performance detergents, water recovery and control systems allow the use of only the resources that are actually necessary while maintaining high standards of cleanliness and fabric protection.”
We put some specific questions to Luca Dal Lago, Managing Director and Technical/Commercial Manager at ITALHYDRO, a company specialising in waste water treatment, including for industrial laundries.
What are currently the main obstacles to water reuse in textile washing processes?
“The first obstacle is still the cost of the raw material. In Italy, despite the increases of recent years, water remains relatively cheap compared to other European countries. Companies with authorised wells may therefore have less economic incentive to invest in water recovery. On the other hand, wastewater discharge costs are rising, making it increasingly attractive to reduce the effluent volumes. Plant size also matters: the larger the treated volume, the lower the relative impact of the investment.”
Which technologies do you use?
“We work with membrane systems, i.e., molecular-separation technologies, hat allow us to obtain a high quality of recovered prowater. Depending on the characteristics of the plant, we can intervene after biological treatment or also use membrane systems during the purification stage. We can recover between 60% and 70% of the water. In some cases, we can reach 85%, but increasing the recovery rate also increases investment requirements and energy consumption. The choice therefore needs to be tailored to the company’s needs and to the availability and nature of the water source. When properly treated, the water can also be reused continuously and, in some cases, may have better characteristics than network water in terms of salinity and hardness. One key parameter to monitor is conductivity, which makes it possible to control salinity and verify that the process is running correctly.”
Can water and energy be recovered together?
“Absolutely. Wastewater can reach temperatures of 60–65 °C. Through heat exchangers, we recover part of this energy to preheat mains water or recovered water. In addition, recovered water retains a higher temperature than that of the mains supply, providing a further contribution to energy savings. Finally, we work on optimising consumption through inverters, sensors and control systems.”
Integrated water management is becoming increasingly central in textile processes, particularly in washing.
What is the main challenge today, and how can it become an industrial opportunity?
Marco Niccolini, Global Sales & Marketing Director at RENZACCI SpA, explains: “The priority is to consume as little water as possible while, at the same time, returning as much clean water as possible to the system. The real challenge is identifying the most effective technologies to achieve both goals. In washing, we address consumption through precise dosing systems, customised programmes and technologies capable of adapting the cycle to the type and quantity of fabric being processed. But reducing consumption is not enough; we must also recover and reuse the water. Recovery must be integrated into the machine without requiring significant additional space. With systems such as EcoCare Renzacci, we recover water directly within the process while also guaranteeing its quality, avoiding problems associated with bacteria, impurities and chemical residues. The programmes must also be calibrated according to the weight of the garments, the fabric and the type of wash. Another fundamental issue is the quality of the water discharged back into the environment. This is why it is essential to work together with chemical-product manufacturers and address the entire supply chain. For many years, we have also been committed to reducing microplastics. With Plastic Guard, we aim to make filtration increasingly accessible. For us, this represents an investment in research, innovation and sustainability.”
How can heat recovery contribute to reducing energy consumption?
“Heat recovery is also crucial. With Special One, we have integrated washing and drying, using water that has already been preheated to about 40 °C, thereby reducing the energy required to reach the required temperature.”
How to combine quality, savings, sustainability and competitiveness?
“It mainly requires research, development, and training. Technology must reduce consumption, recover resources and guarantee quality, but it must also be used to its full potential. That is why manufacturers and users need to work together and invest in training. Only in this way can sustainability become not simply an environmental goal, but a tangible driver of industrial efficiency and competitiveness.”
Water management has become one of the central challenges for the textile industry. For Alessia Miotto, Managing Director of IMESA SpA, the answer lies in a paradigm shift: moving from a consumption-based approach to a circular one, integrating water, energy, technology and data.
Balancing efficiency and sustainability…
“First and foremost, it means reducing water requirements at the source and using only the water that is actually needed. Then comes reuse: water from certain stages of the process can be recovered and redirected to less demanding processes. Filtration and treatment systems, including membrane technologies, now allow us to recover very high percentages of water. But the goal isn’t just to chase the highest percentage; we must also consider energy, costs, and overall impact.”
And how does energy saving fit into this context?
“Water and energy are two sides of the same problem. Heating water requires energy, and when we discharge it hot, we waste both resources. That’s why thermal recovery is strategic: the heat from the outgoing water can be captured and used to pre heat the next cycles.”
Does this so-called virtuous circuit in the laundry stop there?
“No, it can extend to hot air, steam, drying and finishing. The question is no longer simply how much water a machine consumes, but how many resources are required to process one kilogram of textile.”
Can technology, in all its forms, play a significant role in this approach?
“Without a doubt. Sensors, automation and software transform the machine into an intelligent system. We can measure water, energy, processing times, detergents and performance. And we cannot improve what we are unable to measure. The next step is Artificial Intelligence: by analysing data, it can identify anomalies, optimise cycles and support predictive maintenance.”
“In professional textile care, water is no longer simply a resource to be used and treated at the end of the process; it is a central element to production efficiency,” says Antonio Ciccarella, Laundry Division Manager. “That is why ECOSI complements its range of specialist chemical products, formulated to meet each customer’s needs and the characteristics of the water in use, with solutions and technologies designed to address the entire process. “This approach led to the development of WOS+, a solution for recovering process water. It is designed to reduce water withdrawals, optimise consumption and return recovered water to the production cycle. Water recovery reduces the need for fresh supplies and the volumes requiring treatment, improving the plant’s overall efficiency. “This approach is complemented by Microcapta System, which uses Captoplastic technology to capture up to 98% of the microplastics and microfibres that can enter wastewater discharges and sludge. Through a strategic partnership, ÈCOSÌ holds the exclusive rights to Captoplastic technology on the Italian market.”
So, an integrated water management system…
“WOS+ and Microcapta System embody an approach that goes beyond chemical products: chemistry, technology and process expertise work together to maximise the value of customers’ plants, improve performance and reduce environmental impact. This integrated approach to water management turns a challenge into a practical driver of efficiency and innovation.”
Reducing water consumption, limiting the microplastics release and, at the same time, keeping energy consumption under control. This is the direction identified by Electrolux Professional to make textile care more sustainable and competitive. Marco Oleoni, Sales Director Laundry Italy at ELECTROLUX PROFESSIONAL SpA, who addressed the issue, explains the solutions developed by the company to tackle one of the main challenges of professional washing: water management. “We have the opportunity to provide laundries with an innovative system for removing microplastics from the water. It is called Coral Care, a filtration and recycling technology that can be connected to one or three washing machines and monitors the water in real time, separating the water to be discharged from that which can be reused. The system aims to reduce the presence of microplastics by up to 90% and, on average, recovers about 20 % of the discharged water. The percentage depends on the quality of the water being treated. This approach tackles two issues simultaneously: protecting the environment and reducing the consumption of a resource that is becoming ever more strategic for the industry. Sustainability also extends to the stage following washing. With its new generation of professional washers, Electrolux Professional is targeting the spin cycle to reduce residual moisture in linen. The new Compact Power range, part of the 7000 Generation, raises the G-force from 450 to 600, reducing residual moisture from 45% to 40%. That 5% may seem small, but it makes a huge difference,” emphasizes Oleoni. Less water retained in the fabrics means less time required for drying and, consequently, lower energy consumption. The strategy therefore works on the entire process: use less water during washing, extract a greater amount during the spin cycle and reduce the energy required during the drying phase. It is an approach that brings together technological innovation, efficiency and sustainability: not by compromising the quality of the results, but by achieving the same performance level while using fewer resources. “It is not the same washing machine we had twenty years ago,” observes Oleoni. “For Electrolux Professional, competitiveness also depends on the ability to rethink every stage of the production process in order to make it more efficient.”
With more than 300 UV-C systems installed in laundries, SMART UV POWER represents a practical solution for making textile care processes more efficient and sustainable. We spoke with Pascal Kienle, Global Portfolio Manager Textile Care at CHT GROUP.
What industry needs does SMART UV POWER address?
“This technology was developed to combine washing performance with sustainability. By integrating chemistry and physics it enables laundries to reduce water, energy and detergent consumption while maintaining excellent washing results”.
What makes the technology unique?
“SMART UV POWER enables laundries to reduce chemistry and temperature without increasing mechanics or process time. This redefines the Sinner’s Circle. The system is also VAH-listed at 60 °C with hydrogen peroxide. A key benefit is improved wastewater quality. UV-C technology significantly reduces COD and TOC values, helping to decrease the environmental impact of laundry processes. Reduced chemical consumption and lower rewash rates also support more efficient use of water resources”.
What role does UV-C technology play in the washing process?
“UV-C energy activates hydrogen peroxide, allowing washing temperatures to be reduced from 70 °C to 60 °C or even 40 - 50 °C without chlorine or peracids, while keeping excellent washing results. An excellent stain and dirt removal with up to 30 % less chemicals is achieved. Fiber damage remains minimal, whiteness values stay high and double disinfection through UV-C energy and hydrogen peroxide helps counteract contamination in washing ranges”.
What is the value of this technology for the future of the industry?
“Making the process more efficient means using fewer resources without compromising quality or hygiene. This is SMART UV POWER’s contribution to a more sustainable model of textile care.”
We now turn to another water treatment specialist, DALMON WATER SOLUTIONS, and speak with Giorgio Longo, Technical Dept. of the company. “Today, the main challenge to reusing water in textile-washing processes is not a single factor, but the need to balance the required water quality with wastewater variability, energy consumption and system complexity. Water quality is crucial: colour, surfactants, organic matter and salts must all be controlled according to the process and the type of fabric being treated”.
Which is considered to be the most effective technology?
“The most effective technologies generally involve several treatment stages: filtration and clarification to remove solids; biological or oxidation treatments to reduce organic matter; and membranes (particularly ultrafiltration and reverse osmosis) to obtain high-quality water. Advanced oxidation processes or specific adsorption systems can be used to remove colour. The choice always depends on the composition of the wastewater and the required water quality”.
Can the water be recovered?
“Under the right conditions, it is realistically possible to recover a significant proportion of process water, potentially 70–90%. There is no single optimal recovery rate; the real objective is to achieve the highest level of recovery that is economically and energetically sustainable. The recovered water can either be fed directly back into the process or blended with fresh water, depending on the quality achieved and the sensitivity of the process. In repeated cycles, it is essential to monitor parameters such as conductivity, pH, colour, turbidity, COD, and microbiological load, while avoiding accumulation that could affect the washing process or the fabric. Integrating water and energy recovery represents a further step forward: recovering both water and heat simultaneously makes it possible to reduce both water withdrawals and thermal energy consumption, thereby improving the overall efficiency of the plant. The real “holy grail” is therefore not maximum recovery at any cost, but rather finding the point of balance where water savings, process quality, energy consumption, reliability, and economic sustainability converge. In our view, this is the true objective of an industrial wastewater recovery system.”
DETERGO MAGAZINE # OCTOBER 2026
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