AMA Herbal Group has secured its second patent for a proprietary natural rope dyeing process, strengthening its position in the global push toward sustainable and commercially viable textile manufacturing.
The latest patent, recently featured in Business News This Week, protects a technology that enables continuous and uniform dyeing of long yarn lengths using natural dyes.
The innovation is designed to reduce water consumption, lower operational costs and make large-scale natural dyeing more practical for textile mills. According to the company, the process is not currently offered by any other player in the market.
Rope dyeing is a machine-based method most commonly associated with denim production, where yarns are dyed before weaving. However, the technique is not limited to denim and can be applied across a range of textile segments.
In rope dyeing, yarns measuring between 10,000 and 20,000 meters are processed in continuous form, allowing for high-volume output and consistent quality. Conventional natural dyeing methods, by contrast, often rely on yarn in cone form weighing roughly 2 to 2.5 kilograms or in hank form between 0.5 and 1 kilogram.
In the case of hank dyeing, individual hanks must be manually tied together before processing, creating additional labor requirements and extending production timelines. These fragmented steps have historically limited the scalability of natural dye applications in industrial settings.
AMA Herbal’s newly patented rope dyeing system replaces these discontinuous methods with an integrated, end-to-end process. By enabling continuous dyeing, the technology reduces handling time and simplifies workflow on the factory floor.
Also read: SDC Delegation Explores AI and Nature-Based Dyeing with BGMEA
Industry observers say such integration is critical for bridging the gap between eco-friendly innovation and commercial feasibility. One of the major challenges in natural dyeing has been fiber affinity. While indigo has long been used successfully, many other natural dyes have struggled to bond effectively with cotton fibers.
This often required separate and repeated stages, including pre-treatment, dyeing, washing and fixation, each consuming water, chemicals, and energy. These multiple stages increased costs and made natural dyeing less competitive compared to synthetic alternatives.
The patented process developed by AMA Herbal integrates these stages into a single rope dyeing sequence. By optimizing treatment, dye absorption and fixation within one streamlined system, the technology allows a broader spectrum of natural dyes to be used more efficiently on cotton yarn.
The company says this integration not only reduces water usage but also improves color uniformity across extended yarn lengths. Uniform coloration over long stretches of yarn is a key requirement for modern textile manufacturing, particularly in large-scale operations supplying global apparel brands.
Inconsistent dyeing can lead to shade variations in finished fabrics, increasing rejection rates and material waste. AMA Herbal stated that its process delivers consistent color distribution across the entire 10,000 to 20,000 meter rope, meeting industrial quality standards.
The technology has already moved beyond the pilot phase. The company confirmed that the process is being used commercially in two textile mills, where it has produced market-ready yarns with stable quality and competitive cost structures.
Executives say the reduced water consumption contributes directly to lower dyeing expenses, offering mills both environmental and financial incentives.
“This is our second patent and a major step toward strengthening natural dyeing at a commercial level,” said Yawer Ali Shah, Co-Founder and Chief Executive Officer of AMA Herbal Group. “Our goal is to promote environmentally responsible textile production while ensuring the process remains scalable and economically viable for manufacturers.”
The textile sector has faced mounting pressure to curb water use and reduce chemical discharge, particularly in dyeing operations, which are among the most resource-intensive stages of garment production. Technologies that combine sustainability with operational efficiency are increasingly sought after by mills and global brands alike.
With its second patent now secured, AMA Herbal Group is positioning itself as a technology-driven player in natural dye innovation. Industry analysts say scalable solutions such as continuous natural rope dyeing could play a meaningful role in reshaping supply chains as sustainability standards tighten worldwide.
