Ecological concerns have become key issues in the present
global industrial activities. In this context, integrated cleaner
leather processing capable of improving the effluent quality
will be the most appropriate theme for sustainable growth in
leather industry. In this investigation, an integrated leather process
has been explored. Using the optimized dehairing and sodium
hydroxide based fibre-opening process, an integrated
tanning process has been formulated employing a pickle and
basification-free chrome tanning. Experimentally processed
leathers reveal higher percentage of chromium content as compared
to conventionally processed leather. Scanning electron
microscopic analysis of both control and experimental leather
samples shows that the grain surface is clean and separation of
fibre bundles is good, indicating the efficacy of the developed process.
The strength and tactile properties of the experimental
leathers are comparable to that of the control leathers. Composite
liquor analysis shows that COD and TS loads are reduced
by 67 and 78%. The inputeoutput audit analysis
reveals that the experimental leather processing is able to
reduce the total chemical consumption by 91% compared to
control leather processing. In the case of chemicals load on
effluent, the envisaged process provides 95% reduction compared
to control leather processing. The techno-economic feasibility
study shows that the developed process is able to
provide a net saving of US $154 for processing 1 metric ton
of sheepskins, in addition to reducing the effluent treatment
cost. Considering the process followed in developed countries,
where about 2% lime for paste liming, 4% lime for reliming
and 8% sodium chloride for pickling are employed, the application
of the proposed three-step tanning processes leads to
the reduction in chemicals usage by 75%, TS load by 62%.
Consequently, the saving in cost of chemicals compared
with the conventional process followed in developed countries
is US $17 and overall saving is US $171 per metric ton of
sheepskins processed into leathe