Innovation Archives

Chemicals & Materials

Our Approach to Chemical Management

Zero Discharge of Hazardous Chemicals (ZDHC)

We have been the active contributors for ZDHC since its inception in 2011. Our facilities were the first ones in India to be ZDHC audited by two brands a third party in 2012-13. Since then our facilities’ wastewater samples are regularly being tested as per ZDHC wastewater guidelines, which we are disclosing externally on IPE platform and now at ZDHC Gateway. We have also developed single window chemical purchase procedure to prevent the entry of restricted (priority) chemicals in our operations.

Proper Storage and Handling

We strictly adhere to non-usage of restricted chemicals and have a strong governance system in place to ensure proper chemical management through regular audits, trainings and guidelines displayed across our factories. Our chemical management guidelines include proper chemical storage, chemical use, Personal Protective Equipment (PPE) usage and selection, and emergency response training.
Going above and beyond industry standards, our mills and several washing facilities are certified by OEKO-TEX® STANDARD 100, a globally standardized and independent testing and certification system.

Reduction in Chemical Use

We are constantly researching and finding ways to reduce chemical use by substituting certain chemicals in the washing process.

Sustainably sourced materials used at Shahi

BCI cotton
Organic Cotton: Global Organic Textile Standard and Organic Cotton Standards (GOTS, OCS)
Canopy Viscose
Certified Sustainable Viscose
Ecovera (Viscose)
Liva Eco (Viscose)
Recycled Polyester
Tencel
Hemp

A strong focus on sustainable material sourcing has enabled Shahi to achieve (FY 2021)

26% sustainably sourced fabric used in garment manufacturing
46% sustainably sourced yarns used in fabric manufacturing at our mills

Read more about how we created India’s first woven Cradle to Cradle Certified® Gold product.

Energy

Our Approach to Energy Conservation

Environmental Area	Goal	Target Year	FY 2021 Performance	Baseline Year Performance
Energy Baseline year (2018-19)	To have 100% renewable electricity	FY 2026	68%	47%
Energy Baseline year (2018-19)	To have 50% energy consumption from carbon-neutral sources	FY 2026	35%	31%

Renewable Energy

Shahi has set up two solar power plants in Karnataka with capacities of 32MW and 52MW. Our upcoming strategy aims to reach the goal of 100% of Shahi’s power consumption to be generated by renewable sources by 2026.
In addition, we have invested in seven wind turbines, which generate the equivalent of 8.5% of Shahi’s total electrical energy consumption. Learn more about Shahi’s journey to 100% renewable energy.
We have converted most of our high-speed diesel (HSD) fired boilers into agro-waste (biomass) or PNG-fired boilers. As a result, over 35% of the energy consumed in our factories is carbon neutral.
By generating power through steam turbines, we are reducing our power consumption from other sources, leading to a reduction in GHG emissions.

Improving Energy Intensity

Across our factories and mills, we have launched several initiatives and installed new technologies to reduce our energy consumption. These initiatives include:

Replacing T8 lamps with LED lighting across leading to 50% power savings
Replacement of clutch motors with servo motors in sewing machines
Comprehensive air leak audits to prevent compressed air leakages
Usage of occupancy sensors in sparingly used areas
Flash steam recovery
Self power generation from process steam

Green Building Design

Our new factories, since 2016, were designed and built to harness sunlight to illuminate our shop floors. The architecture facilitates natural ventilation that reduces heat dissipation from electric lighting fixtures.

At Shahi, we recognize the significance of energy's dire impact on climate change. Investing in Green Building principles minimizes our energy consumption significantly in the long run. Green Building Design.

Water

Our Approach to Water Conservation

Environmental Area	Goal	Target Year	FY 2021 Performance	Baseline Year Performance
Water and Wastewater Baseline year (2021-22)	To have 85% recycled water used for industrial purposes in garment units	FY 2024	80%	2021-22 is the baseline year
Water and Wastewater Baseline year (2021-22)	To have 75% recycled water used for industrial purposes in textile mills	FY 2024	80%	2021-22 is the baseline year

Read more on our water efficiency in our Denim Operations.

Recycling and Reuse

Our advanced effluent treatment plants (ETPs) provide a highly efficient treatment of waste water, enabling the recovery of good quality water to be reused in our production processes.
Domestic effluent (sewage) is also treated through Sewage Treatment Plants (STPs) and reused in washrooms, for ash quenching, horticulture and dust control.
Most of our wet processing units use treated process water, helping the facilities to achieve zero liquid discharge (ZLD).
We are continuously reducing our dependence on fresh water by improving our recycling and reuse efforts through better technology.

Improving Water Intensity

At both our factories and mills, we are constantly researching, developing and introducing new technologies to become more water efficient and reduce consumption. Some of our recent initiatives include:

Waterless washing technologies such as eFlow and Ozone
Use of efficient wash-off chemical
Condensate water recovery from boilers and dryers
Reverse Osmosis (RO) reject for screen and drum washing
Installation of aerators at water taps which enables up to 20% water savings

Rainwater Harvesting

Rainwater harvesting: Our rainwater harvesting systems at Shimoga and other facilities help recharge groundwater levels.

Waste

Shahi’s Waste Management Policy outlines our efforts to minimize waste at the source, right from conceptualization and design, to how we use raw materials. We are mapping waste streams, creating traceability, and exploring circularity with industry partners. The two types of waste generated in garment manufacturing are called hazardous and non-hazardous. All our hazardous waste is disposed of by vendors authorized by the Pollution Control Board, and non-hazardous waste is sold to vendors who recycle, downcycle or upcycle it.