Case Study: HandMade Stone - Redefining Denim Finishing

The Challenge

For decades, denim’s iconic worn-in look came at a steep cost. Traditional pumice stonewashing:

• Consumes 600 tonnes of pumice per million garments,

• Creates toxic sludge that pollute waterways requiring expensive resources to clean up

• Damages expensive finishing machines, driving up operational costs,

• And raises questions about the long-term sustainability of denim finishing.

Brands are caught in a bind: consumers demand the authentic stonewash pumice aesthetic, but the environmental and commercial costs are unsustainable.

The Solution

Enter HMS (HandMade Stone) by Baytech Sustainable Technologies, a patented pumice-free finishing stone developed in Turkey after decades of first-hand experience in denim laundries.

• 90% Stone Reduction: Replacing pumice with durable, reusable stones.

• Cleaner Operations: Eliminates toxic sludge, reduces water and energy consumption, keeps machines cleaner for longer.

• Aesthetic Integrity: Maintains the same worn-in look that pumice delivers, ensuring seamless adoption for brands and consumers.

• Certified Sustainability: The only stone to achieve “green” status on the EIM grading system, supported by a portfolio of global certifications.

Thomas Leary, HMS Global Sales Director, explains:

“With pumice you’re using about 600 tonnes per million garments. With us you go down to 16 - you’re reducing it by 90%. And to be able to sell your product, you also have to have that aesthetic look. The big idea of HMS is maintaining the same aesthetic look of pumice… you’re getting more with less.”

The Results

• Environmental Impact: Massive reduction in resource use and waste, helping brands meet ESG and compliance goals.

• Cost Savings: Extended machine life and lower maintenance costs.

• Commercial Validation: Already adopted at scale by some of the world’s leading denim players.

As Thomas shared:

“Now we’re official vendors with Levi’s, with Kontoor, and then Inditex and H&M.”

Why It Matters

HMS proves that sustainability, creativity and commercial viability can co-exist. By preserving the look consumers love while eliminating the waste brands can’t afford, HMS offers a blueprint for the kind of innovation the fashion industry needs: scalable, practical, and profitable.

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HMS is part of the Future Fashion Assembly community of vetted innovators driving measurable impact across fashion’s value chain.

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