From the Sector

Garment Tech Istanbul 2025, the comprehensive exhibition of the garment and ready-to-wear sector, will host global brands of sewing machines and the latest technologies. Manufacturers including Juki, Yuki, Brother, Dürkopp Adler, Pfaff Industrial, Pegasus, Siruba will exhibit hundreds of types of sewing machines such as industrial and household, automatic, zigzag, chain, overlock and interlock at Garment Tech Istanbul 2025.

During the 4-day exhibition, visitors will be able to experience the functionality of different sewing machines equipped with innovative designs, high efficiency and user-friendly features, get information from experts and discover industry trends.

Sewing Machine Sales to Gain Momentum
As of January-June 2024, Turkiye's sewing machine exports increased by 10.15% to USD 1.608 billion. Among these, the export volume of industrial sewing machines reached 2.28 million units. Among the largest markets, India, Vietnam, Pakistan and Brazil stand out, with exports to Pakistan in particular showing a huge increase of 160.46%. Turkiye's exports in Asia, Latin America and Africa showed strong growth, while its markets in Europe and North America declined slightly. Garment Tech Istanbul will significantly contribute to strengthening sales and international exports by increasing interest in Turkiye's sewing machinery sector.
The Garment Tech Istanbul; Garment, Embroidery Machines Spare Parts and Sub-Industry Exhibition, which will be held at the Istanbul Fair Center (IFM) between June 25-28, will increase interest in Turkiye's sewing machines sector and make a significant contribution to the strengthening of sales and international exports. Participating companies will have the opportunity to start new collaborations as well as increase brand awareness.

The sewing machine sector has evolved rapidly in recent years with many technological innovations. Digital and smart machines allow users to easily select sewing patterns, and adjust speed settings and automatic thread insertion, while automated sewing functions make things faster and more error-free. Automation systems in industrial machines make production processes more efficient. While machines run quieter thanks to electric motors, IoT technology enables remote monitoring of machines and more efficient management of maintenance processes.

The exhibition, where local and foreign manufacturers focusing on R&D and innovation will meet global buyers, will host industry professionals looking to implement new technologies and direct their investments. Company managers who want to produce flawless garments quickly and cost-effectively, increase their capacity and expand their machinery will be able to experience many sewing machine functions and direct their investments at Garment Tech Istanbul Exhibition.

Avgol, an Indorama Ventures company, celebrated the opening of its new high-speed, high-capacity flexible multiple beam nonwovens production line at its facility in Mocksville, NC. It represents the successful realization of a $100 million investment.

In addition to the new production line and as part of the investment, Avgol has installed a state-of-the-art 3-layer lamination line that further expands the company’s nonwoven composite capabilities. Engineered with precision temperature controls, high-speed bonding technology, and an integrated quality inspection system, this advanced machine efficiently fuses three layers to produce lightweight, durable composites with exceptional strength and consistency. Designed to meet the highest quality and performance standards, it reinforces Avgol's commitment to delivering top-tier products and setting new industry benchmarks in nonwoven composite manufacturing.

The inauguration of the new nonwovens production line and beginning to run commercial products is a pivotal step in Avgol’s strategic roadmap, setting the stage for advanced manufacturing capabilities and enhanced production efficiency.

Key highlights of the new production line include:

• Technology: The new line integrates the latest Reicofil manufacturing technology with bico capabilities, ensuring precision, speed, and superior quality control.
• Capacity: With enhanced high-loft production capabilities, Avgol is now better equipped to meet current and future market demands for hygiene products.
• Sustainability: Emphasizing environmental responsibility, the new facility integrates energy-efficient systems, reduced waste protocols, and innovative processes for manufacturing lightweight products.

Over the past 30 years, Monforts and its long-standing partner, Bengal Technology and Engineering, have realised over 100 fully integrated line installations in Bangladesh.

At the forthcoming Dhaka International Textile & Garment Machinery Exhibition (DTG), specialists will be on hand to provide expert advice on the wide range of services that are being provided by Monforts to the region’s dyeing and finishing sector.

The DTG takes place at the International Convention City Bashundhara (ICCB) in Dhaka from February 20-23 and will showcase the technologies of over 1,000 textile machinery brands and suppliers from 31 countries across its nine halls.

The successful 30-year partnership between Monforts and Bengal Technology and Engineering in Bangladesh has grown in parallel to the rapid rise of the nation’s textiles and apparel sector – from just a handful of manufacturers to over 6,000 factories today – and in particular, its growth into the world’s second largest exporter of readymade garments (RMGs).

Hoping to build on this success, the Bangladesh government has now initiated plans to achieve exports of RMGs worth $50 billion by as early as this year – and approaching $100 billion by 2030.

To realise this, however, the reinforcement of a textile manufacturing backbone will become increasingly crucial, and Monforts contributes to ensuring the Bangladesh industry continues to grow sustainably.

Monforts has completed the installation of a Baldwin TexCoat™ G4 digital spray unit at its Advanced Technology Center (ATC) in Mönchengladbach, Germany.

It has been successfully integrated into one of the two full-size Montex stenter lines at the ATC and is now available for full customer trials, especially for making full use of the latest advanced sustainable finishing chemistries supplied by Archroma.

BW Converting’s TexCoat G4 enables softeners, antimicrobials, durable water repellents, flame retardants and many other water-based chemicals to be precisely applied to textile surfaces, and in combination with industry-leading Montex stenters can reduce water, chemistry and energy consumption by up to 50% compared to traditional pad application processes.

Monforts is providing vital support to dyeing and finishing manufacturers in their development projects, successfully boosting the quality and performance of many new finished products while at the same time maximising productivity and resource utilisation

“Our ATC houses two full Montex stenter finishing lines engineered to accommodate an extremely diverse range of processes, in addition to a Thermex range for the continuous dyeing of denim and other woven fabrics, a full color kitchen and a number of lab-scale systems for smaller batch trials,” says Monforts Head of Sales for South-East Asia Hans Wroblowski. “It enables our customers to test their own textiles and technical fabrics under fully confidential, real production conditions and using the results from these trials we are also able to make recommendations for improving many fabric finishes.

“The new TexCoat installation will make an important contribution to what we can achieve and we are excited to be working together with Archroma and Baldwin to bring further transformative change to the dyeing and finishing space.”

“This partnership is already creating a buzz in the industry and we have several textile manufacturers lining up to take advantage of running production trials at the ATC,” adds Rick Stanford, vice-president of global business development for textiles at BW Converting. “Together we are in a position as never before to accelerate the pace of transformative change in the dyeing and finishing space that will result in significantly lower energy, chemicals and water consumption with increased productivity and higher quality.”

“With the extension of our long-standing partnership with Baldwin – now including the processing expertise and knowhow of Monforts – the development of new concepts for chemical functionalisation and coloration will be taken a step further,” says Michael Schuhmann, Global Market Segment Manager for Technical Textiles at Archroma Textile Effects. “Additionally, we can now demonstrate potential savings and performance levels under actual industrial conditions, providing mill partners with clear proof of efficiency without disrupting their production.”

Japanese computerized flat knitting technologist SHIMA SEIKI MFG., LTD. of Wakayama, Japan, together with its Indian sales representative Universal MEP Projects & Engineering Services, Ltd., will participate in the upcoming Garments Machinery Manufacturers & Suppliers Association (GMMSA) Expo India 2025 exhibition to be held in Ludhiana, India next month.

N.SVR®183
SHIMA SEIKI will be exhibiting its WHOLEGARMENT® knitting technology whereby an item can be produced in one entire piece on the machine without linking or sewing. Its N.SVR®183 WHOLEGARMENT® knitting machine produces WHOLEGARMENT® knitwear using every other needle in fine gauge. N.SVR®183 is equipped with the R2CARRIAGE® system and a compact, lightweight carriage for high productivity. Shown in 21G at the GMMSA Expo, N.SVR®183 is an ideal machine for flexible, entry-level WHOLEGARMENT® production, with the versatility to respond to fluctuating market demand.

N.SSR®112
Meanwhile the N.SSR®112 is a computerized flat knitting machine that offers leading technology in an economical yet reliable package. Featuring industry-leading innovations such as the R2CARRIAGE® that yields quicker carriage returns for greater efficiency, spring-type moveable sinker, DSCS® Digital Stitch Control System, stitch presser and takedown comb, Made-in-Japan quality, reliability and productivity, as well as user-friendliness and cost-performance combine to satisfy the high expectations of the world’s, and India’s, fashion industry. N.SSR®112 is even capable of WideGauge® knitting whereby a number of different gauges can be knit into a single garment.

SDS®-ONE APEX4 and APEXFiz®
SDS®-ONE APEX4 3D design system and APEXFiz® subscription-based design software support the creative side of fashion from planning and design to colorway evaluation, realistic fabric simulation and 3D virtual sampling. Virtual samples are a digitized version of sample making that are accurate enough to be used effectively as prototypes, replacing physical sampling and consequently reducing time, cost and material that otherwise go to waste. When a design is approved for production, knitting data which is automatically generated can be converted easily to machine data, allowing smooth communication for digitally bridging the gap between design studio and factory. SDS®-ONE APEX4 and APEXFiz® help to realize sustainability while digitally transforming the fashion supply chain.

Uster FiberQ automated raw material management generated more than 2,000 laydowns in a year for Sagar, one of India’s leading spinners. The results delivered consistent yarn quality and optimized process efficiency – giving a payback period of three months.

Sagar is taking advantage of the new annual subscription format, which includes the software solution plus valuable advisory services from Uster expert technologists.

After one year using FiberQ, A.K. Saini, Chief General Manager Operations at Sagar Manufacturers Pvt. Ltd., reported: “We have seen better fiber utilization, significantly improved yarn quality consistency and elimination of seldom-occurring faults such as white specks and barré. The overall outstanding results convinced our management about the value of FiberQ and we confirmed the renewal of the subscription services of FiberQ and the 360Q platform.”

Sagar insists on consistently high standards in yarn quality and performance. The company wanted to go even further, by optimizing its manufacturing operations and achieving maximum fiber yield.

Sagar Manufacturers Pvt. is renowned for excellence, in both its home country of India and the global textile marketplace, as a producer and supplier of top-class cotton yarns and knitted greige fabric. Saini says: “Our strategic focus is on integrating advanced technology and eco-friendly practices, for creative solutions which drive excellence in manufacturing performance and ensure customer satisfaction.”

Before FiberQ, the company was already proud of the excellent raw material management processes in its spinning operation. It was a determination to improve still further in both production efficiency and consistent quality which led to the decision to implement the Uster FiberQ raw material management solution.

Sagar has always embraced new technologies – especially those focused on innovation and automation – and it was naturally one of the first adopters of the FiberQ raw material management solution. FiberQ combines advanced technology and textile expertise to automate many tasks previously done manually. So it became a very interesting value proposition for progressive spinners like Sagar. The automated, intelligent, reliable and easy-to-use system minimized manual efforts but also provided consistent results. Uster’s end-to-end solution also offers access to continuous improvements such as supplier statistics and fiber-to-yarn correlation, which will add even more value in future.

Impact on production
Sagar figures show that yarn realization has increased by 0.3% to 0.5% on average and it has eliminated the need for ‘cut and creel’ – a big advantage in terms of efficiency and fewer changes in production. During the year, FiberQ generated more than 2,000 laydowns for all production units in a very efficient, fast and easy way. Another plus was the easily accessible laydown history and the visibility of the impact of different cotton lots in use.

Customer feedback has also been strong. Sagar’s improved quality consistency was said to have resulted in better fabric appearance. And since Sagar can now provide customers with bigger yarn lot sizes with the same quality and color properties, they can produce larger, uniform batches of knitted and dyed fabrics and save manufacturing costs.

Advisory service benefits
FiberQ is not only a software solution. It comes with advisory services from expert Uster textile technologists. The FiberQ advisory services ensure there is always a textile engineer with mill experience and deep knowledge available to support the spinners. As well as taking care of all aspects of installation, there are periodic assessments to track quality status from fiber to yarn, which is a unique competence of Uster and a highly appreciated element of the service.

FiberQ is offered as a yearly subscription service. For the industry, the idea of subscribing to a software service for raw material management is quite new, although it has been established for many years in other fields.

The International Textile Manufacturer Federation has published its International Textile Industry Statistics (ITIS) on productive capacity and raw materials consumption in the short-staple organized (spinning mill-) sector in virtually all textile-producing countries in the world. ITMF has used a new calculation method and reviewed past time series.

The estimated global number of installed short-staple spindles reached 232 Mio units in 2023 and the number of installed open-end rotors grew to 9.7 Mio (see Fig. 1 and 2). Capacity building is still disproportionally targeting Asia. The number of installed air-jet spindles soared to 637 thousand. Outside Asia, the main capacity increase was registered in Türkiye.

Global Installed Capacities and Raw Material Consumption in the Short-Staple Organized (Spinning Mill-) Sector of the Textile Industries (1993-2023) The number of installed shuttle-less looms increased to 1.7 Mio in 2023 (see Fig. 3). Total raw material consumption in the short-staple organized sector slightly decreased to 43 Mio tons (see Fig. 4). Global consumption of raw cotton and cellulosic short-staple fibers decreased by -4.4% and -2.9%, respectively. Consumption of synthetic short-staple fibers increased by 0.5%.

SAATI Germany, a leading manufacturer of highly developed technical fabrics, has further optimised its production processes by using innovative measurement and control technology from Mahlo.

The globally active SAATI Group produces filter fabric for blood transfusion devices, aramid fabric for bulletproof vests and functional fabric for mobile phones and tablets, among other things. SAATI is known for its high precision and quality, which is maintained at all stages of production.

The installation of a Mahlo distortion control system Orthopac FMC-15 and a Famacont PMC-15 yarn density meter in the outfeed of a stenter frame was a further step in this optimisation process.

As Saati produces highly technical fabrics, the exact thread count (up to over 300 F/cm) is an essential quality feature. The PMC-15, a camera-based measuring system, can continuously record and log this parameter. At the same time, the FMC-15 records residual distortion and contributes to the elimination of so-called back sheet distortion in the fabric by automatically controlling the take-off roller of the stenter frame. This ensures the consistently high quality of the end products and reduces potential sources of error.

The investment in these systems proved so successful that SAATI initiated the next stage of process optimisation in 2024. „With the installation of an Orthopac GRVMC-15 straightening machine before the infeed of the stenter frame, we have further perfected the control of fabric
quality,“ says Operations Manager Thomas Brockmeier. The heavyweight among the Mahlo straightening systems with a working width of 2,800 mm enables SAATI to correct skew and bow distortions in the raw fabric even before the stenter frame. This is because a weft yarn that is only slightly skewed or curved can render the fabric unusable or visually unfit for use.

By combining the GRVMC-15 with the FMC-15 already installed in the outfeed, SAATI now has a fully automatic system that offers maximum monitoring and control options. The co-operation of these two technologies enables the company to deliver precisely shot-straight items. „I am delighted that we were able to complete the project so successfully,“ says Brockmeier.

International technology group ANDRITZ has inaugurated a new technical center in Montbonnot, France, dedicated to advancing solutions for dry molded fiber production.

Dry molded fiber (DMF) production uses a nearly waterless process to convert cellulose fibers into three-dimensional products for sustainable packaging. Based on its strategic partnership with the Swedish DMF pioneer PulPac, ANDRITZ is now able to offer complete dry molded fiber lines.

The new technical center with its pilot line will support ANDRITZ’s development of industrial-scale solutions for high-speed, turnkey dry molded fiber production plants for the packaging industry. It will also enable customers to conduct trials, receive support on R&D projects, and create new products with customized shapes and barrier properties.

Andreas Lukas, Senior Vice President of ANDRITZ Nonwoven & Textile, states: “Wood pulp processing has been a core competence of ANDRITZ for a long time. Our new pilot line is an important step in advancing our solutions for responsible convenience packaging from wood pulp. By combining ANDRITZ Dan-Web’s airlaid forming capabilities with PulPac’s molding technology, we are striving for the highest capacity, product quality and flexibility in this field.”

UMAC, a member of the EREMA Group, is expanding its ReadyMac product line with a new 60 hertz version. This means that the immediately available plastics recycling solution can now be deployed worldwide. The standardised machine with its particularly attractive price-performance ratio will be presented in its new look for the first time at Plast Eurasia from 4-7 December 2024 in Istanbul.
    
The ReadyMac celebrated its market launch at K 2022. The recycling system, which is produced in stock and therefore available at short notice, has since established itself successfully in the 50 hertz version, particularly on the European market. Based on this success, UMAC is now also offering the ReadyMac 500 in a 60 hertz version. "The ReadyMac is suitable for a wide range of materials and degrees of contamination, processing film, flakes and regrind into high-quality recycled pellets. The fixed price of just EUR 375,000 makes it an attractive proposition," says Michael Köhnhofer, Site Manager at UMAC. The machine is produced in small series at the St. Marien site.

The ReadyMac is based on EREMA's proven TVE technology, in which degassing occurs after filtration. Equipped with a robust SW RTF® screen changer filtration system, the recycling machine processes both printed and contaminated waste. The multipurpose screw handles a wide range of materials efficiently and reliably. With a throughput of up to 500 kg/h for LDPE, LLDPE, MDPE, PP, PS, PC, ABS and up to 450 kg/h for HDPE, the ReadyMac 500 is a true all-rounder. In addition, the two frequency converters on the main drives (preconditioning unit and extruder screw) ensure consistently high throughputs and quality for a wide variety of material types, such as regrind, film or nonwoven, even without changing the screw. This enhances both flexibility and productivity. The frequency converters are now included as standard with the ReadyMac.