Sustainable Wet Processing Technologies for the Textile Industry: A Comprehensive Review

The textile industry ranks among the highest water-consuming sectors globally, with annual usage reaching billions of cubic meters. In manufacturing, wet processing, including dyeing, printing, and finishing, accounts for 72% of this water demand. These stages not only require vast water volumes but also produce wastewater containing hazardous chemicals, polluting ecosystems and reducing soil fertility. Furthermore, the energy-intensive nature of these processes, combined with a heavy reliance on fossil fuels, contributes significantly to greenhouse gas emissions. In response to these environmental challenges, innovative technologies have emerged, such as waterless dyeing using supercritical carbon dioxide, digital printing, ultrasonic-assisted processing, foam dyeing, laser-based denim finishing, and dope dyeing for man-made fibers. These methods drastically reduce water consumption, lower energy use, and minimize emissions while maintaining textile quality. However, the widespread adoption of these alternatives faces challenges, including high implementation costs, process scalability, and compatibility with existing infrastructure. This review critically explores current advancements in sustainable textile wet processing, analyzing their effectiveness, limitations, and industrial viability. By addressing these challenges, the textile industry can transition toward environmentally friendly and resource-efficient manufacturing processes.