From the Sector

At the forthcoming Texprocess, Techtextil and Heimtextil shows taking place in Frankfurt from June 21-24 – members of the Swedish Textile Machinery Association TMAS will be showcasing a range of solutions aligning with the growing trend for more localised and automated textile manufacturing.

Digitalisation and the push for more sustainable, shorter and less expensive supply chains are currently making manufacturing in high-cost countries within Europe more attractive and there have been many other contributing factors to this over the past two years.

The Covid-19 pandemic exposed the vulnerability of many countries to shortages of essential items like PPE while at the same time making the full exploitation of new digital options essential during national lock-downs and long periods of restricted travel. The escalating cost of global transportation, as well as the growth of online retailing and the associated benefits of on-demand digital manufacturing, are further reinforcing the many benefits of short-run and near-shore new operations.

Secure supply
At Texprocess, for example, Eton Systems will be unveiling its latest Ingenious software solution which further enhances the company’s Opta Unit Production System (UPS) introduced in 2021.

“Our automated technology has already had a great impact on the productivity of thousands of garment production lines,” says Eton’s Managing Director Jerker Krabbe. “Our systems help producers across the world to reduce repetitive manual tasks and increase efficiency, which evens out some of the differences between production in high and low-cost countries, making reshoring a feasible option. Creating a diversified production portfolio with a mix of production facilities, some closer to home, makes for a more secure product supply.”

Flexibility
Imogo meanwhile recently installed the first industrial scale dyeing system in Sweden for many years. The Dye-Max spray dyeing line has the potential to slash the use of fresh water, wastewater, energy and chemicals by as much as 90% compared to conventional jet dyeing systems. It is capable of carrying out the application of a wide range of fabric pre-treatments and finishing processes, providing users with unbeatable flexibility in production.

“Here in Scandinavia, we are currently seeing an explosion of companies developing sustainable new cellulosic fibres – many from waste clothing – but a problem is that all of the environmental benefits they deliver can potentially be lost in the further processing, and especially in conventional dyeing,” observes the company’s Founding Partner Per Stenflo. “The Dye-Max system positively addresses this, but interest in it has not just been confined to Europe. We are currently seeing a lot of activity in Turkey – largely as a near-shore partner to European brands – but also in Bangladesh.”

Robotics at Heimtextil
ACG Kinna Automatic specialises in automation solutions for filled products such as quilts, pillows and mattresses and its live demonstrations of robotics in action have proved a magnet for visitors to Heimtextil. This year’s show will be no exception.

“The use of robotics is now standard across many industries dealing in solid goods, but the handling of soft materials such as textiles is a little more complex,” says Managing Director Christian Moore. “Nevertheless, it’s something we have successfully mastered, and our robotic systems are proving highly beneficial to their users. There is no ‘one-size-fits-all’ solution when it comes to automation and our approach is always to carefully examine where it will make the difference in each bespoke system. A focus is on identifying and eliminating bottlenecks which will increase product flows.”

During the Covid-19 pandemic, ACG Kinna drew on all of its automation know-how and extensive network of contacts to build a new nonwovens fabric converting and single-use garment making-up plant in a matter of weeks, in order to supply the Swedish authorities with urgently-needed medical gowns.

Instant colour
Localised textile production is also booming in the USA, where Coloreel has recently secured multiple orders for its instant thread colouration technology via its US partner Hirsch.

“Coloreel technology enables the high-quality and instant colouring of a textile thread while it is actually being used in production and can be paired with any existing embroidery machine without modification, while also making it possible to produce gradients in an embroidery for the first time,” explains VP of Sales Sven Öquist.

“Advanced rapid colour formulation software and high-speed drive technology allow a single needle to carry out what it previously required many multiples of them to do – and with much more consistent stitch quality. By instantly colouring a recycled white base thread during production, our system enables complete freedom to create unique embroideries without any limitations. Colour changes along the thread can either be made rapidly from one solid colour to another, or gradually, to make smooth transitions or any colouring effect desired. This provides big benefits when it comes to sustainability and design creativity.”

Milestone
Svegea will be promoting its latest EC 300 collarette cutting machine at Texprocess 2022. This machine is used by garment manufacturers around the world for the production of tubular apparel components such as waistbands, cuff and neck tapes and other seam reinforcements. With its E-Drive 2 system and fully automatic FA500 roll slitter, the EC 300 has an output of around 20,000 metres per hour.

“Advances in automation are only making the specialised, bespoke machines we engineer even more efficient and we are expecting a very busy year,” says Managing Director Håkan Steene. “The garment components our collarette cutters produce make it logical for them to be integrated into the operations of making-up operations, wherever they are.”

Sensors
The advanced yarn tension monitoring technologies of Eltex of Sweden meanwhile play an essential role in rectifying defects in  weaving, tufting and composite reinforcement operations.

“A correct tension of the warp and weft threads ensures proper machine operation,” explains Eltex Global Marketing and Sales Manager Anoop K. Sharma “The constant tension monitoring and automatic control of the tension of the thread help to overcome unnecessary problems.

“We continue to make advances in both the hardware and software of our tension monitoring systems, such as the EyE™ for the warping process. With the EyE™, the yarn tension values from all yarns are continuously updated and displayed on screen. In addition, tension values outside the warning level are indicated both on the sensor’s LEDs and on the screen for complete quality control. No fabric can be woven without the appropriate and correct tension.”

The next edition of Techtextil North America will take place in Atlanta from May 17^nd to 19^th.  At Atlanta ACIMIT, the Association of Italian Textile Machinery Manufacturers, and Italian Trade Agency organize an Italian Pavilion, where 17 Italian machinery manufacturers involved in the production of machines for technical textiles will show their innovative solutions.

ACIMIT members exhibiting in the Italian Pavilion are: 4M Plants, Aeris, Arioli, Computer House, Fadis, Flainox, Guarneri Technology, Ima, Kairos Engineering, Mcs, Ramina, Siltex, Stalam, Testa, Willy.

The US textile industry is one of the top in US manufacturing sector, with a sales volume of exceeding US$ 64 billion in 2020, with approximately 300,000 workers and about 15,000 companies. The industry's strength lies in cotton, man-made fibers, and a wide variety of yarns and fabrics, including those for apparel and industrial uses.

In 2021, the USA represented the third market for Italian textile machinery exports, behind China and Turkey. In 2021 January-September period the value of Italian sales to US market was 93 million Euros, an increase of 74% compared to the same period of the previous year.

• Experienced government affairs professional with EPA background to advocate for the nonwovens association in public policy forums

INDA, The Association of the Nonwoven Fabrics Industry, has named experienced policy advocate Jennifer “Jen” Greenamoyer as its new Director of Government Affairs to raise the association’s profile in Washington, D.C. She brings 25 years of experience at associations, the U.S. Environmental Protection Agency (EPA) and on Capitol Hill.  

Most recently, she was senior government relations liaison and the principal lobbyist at the American Institute of Physics (AIP) for 15 years, where she represented the association to Congress and lobbied for appropriations. Greenamoyer has strong expertise in science policy and education that will enhance her role as an information resource for INDA members, staff, and others on government affairs’ matters affecting the industry.

She began her career working at the EPA in the Office of Water and then the Office of Policy. Greenamoyer also trained EPA staff on regulation development and worked on small business regulatory relief. On Capitol Hill, Greenamoyer worked as professional staff for the House Committee on Small Business where she specialized in regulations about environmental and labor issues.

As Director of External Affairs for the Sea Grant Association, she secured annual appropriations, monitored legislative developments, and represented the association to federal agencies and the Administration on issues of interest, funding opportunities and joint programs.

At INDA, she will serve as the liaison between the industry and government legislative and regulatory bodies by preparing formal submissions to the federal government articulating industry positions, and representing INDA on the Industry Trade Advisory Committee for Textiles and Apparel (ITAC 13) among other responsibilities in this key position.

National Council of Textile Organizations (NCTO) President and CEO Kim Glas, representing the full spectrum of U.S. textiles from fiber through finished sewn products, welcomes the appointment of Jennifer Knight as Deputy Assistant Secretary for Textiles, Consumer Goods and Materials at the U.S. Department of Commerce.

Knight will oversee the Office of Textiles and Apparel (OTEXA), the Office of Materials Industries and the Office of Consumer Goods within the International Trade Administration’s Industry and Analysis unit.

Statement from NCTO President and CEO Kim Glas:
We applaud the Biden administration for appointing Jennifer Knight to serve as the Deputy Assistant Secretary for Textiles, Consumer Goods and Materials.
Jennifer’s extensive and successful career in U.S. textile manufacturing, as well as her experience in setting up international operations in regions such as Central America, is an enormous asset as she takes on this critical role.

As onshoring and nearshoring efforts gain momentum amidst the global supply chain crisis, Jennifer’s appointment could not have come at a more pivotal time. We couldn’t be more delighted with her appointment and strong familiarity with our sector and beyond.  Jennifer will be a strong advocate for American workers and industries, and we look forward to working with her on the U.S. textile industry’s top priorities in the months and years ahead.

For most textiles, finishing processes are not actually the last stage. Products often need an extra touch of expertise to make them perfectly ready for the customer. At this point in the value chain, that usually means manual tasks – but now there are technical solutions and intelligent systems which can handle complex operations better, while adding extra value and assured quality.
Automation brings reliability and efficiency, ultimately saving costs to produce the right quality every time. Swiss companies are specialized in many of these disciplines, with machinery for fabric inspection and presentation, labelling and tracking, folding and packaging. They have the technology to inspire a new vision at the post-production segment of the textile manufacturing processes. Optimization of workflows, with bottleneck management, is an obvious potential benefit. And it delivers measurable returns on investment. The wider picture with automation will prepare companies for the IoT and Industry 4.0.

New business models
The advantages of automation in mills with high-volume production are obvious: consistent quality, increased efficiency, waste reduction in some cases, as well as significant medium-term cost reductions in every case.
That description focuses on the aims of modern mills in low-cost markets. But producers in Europe and USA could reach out for more. For them, automation could be a game-changer, offering unique new opportunities.
Reshoring is a growing trend now. It shows great potential and is definitely driven by sustainability and changes in consumer mindsets. “We believe that the time is right – the machines and solutions certainly are – to push automation also to the very end of the production line, replacing intensive manual work and take the chance for reshoring. The current situation is kind of a transition time which is expected to last for a couple more years in the textile industry,” says Rueedi. He adds that any investments in these prime markets pay off much faster because of higher labour costs.
Innovation transformed through automation can do much more than simply replacing the nimble fingers of humans. It also enables new business models, guaranteeing prosperous future business, alongside greater job security.

Digital workflow and process control
The Swiss company Maag Brothers is a leading supplier of high-end machines for quality assurance in the final make-up processes, specifically fabric inspection, plating/folding, selvedge printing and packaging. Maag reports on a practical example from a mill in India which recognized the potential of automation.
An analysis at the customer’s mill identified the main goals as modernization of the workflow at quality control and packing processes. Maag’s new system covers tasks from fabric inspection to dispatch, and offers transparent and easily adjustable processes with real-time process control. It’s a digital solution, resulting in a slim organization, paperless, and the basis for further optimization towards Industry 4.0 to exploit its full potential. The customer’s own calculation showed a ROI for the installation at less than three years – along with a reduction in manpower and savings in fabric costs for shade samples.

Perfectly labelled, efficient data...
Smooth processes start with a label. Swiss company Norsel is an expert in grey fabric labelling systems, for piece tracking through all textile processes. High-quality label printing and proper sealing on all kind of fabrics ensure readability and sustainability after dyehouse processes such as mercerizing, high temperature dyeing and even hot calendering. No roll mix-up during dyeing, easy sorting of fabric rolls and rapid delivery make processes in the mill much more efficient. Using RFID codes lifts fabric inventory control to the highest level, with all information readily transferred to a database and integrated through any ERP software.
It’s a foolproof way to avoid the risk of human errors from hand-written notes on grey fabrics and article sheets, by opting for reliable, secure and forward-looking solutions.

Sample collections – the silent salesmen
First impressions count, so fabric producers like to present their collection perfectly – and that’s only possible with automated solutions. Swiss producer Polytex continuously refines its solutions, underlining its leading position in sample making equipment. Fully-automatic high-performance sample production lines are designed to satisfy the highest expectations. Fully-automatic lines or robotic machines set the standards for quality and performance. Even the most demanding clients can achieve their goals with impeccable samples, quickly and efficiently made, for flawless collections that are sure to impress.

Automation drives buying
First impressions are also the trigger for quick purchase decisions. The proof is there on every store shelf. Customers of Espritech are also well aware of it. They trust this Swiss producer of automated folding machinery to provide the final touch of class to home textiles and apparel products before they go on display. The folding systems are generally large mechatronic devices, loaded with latest technologies in mechanics, electronics, sensors and pneumatics. “Textile producers are amazed how folding machines solve the tricky task of reliably handling chaotically behaving materials. They see process optimization potential and the impact. We observe a slow but continuous change of mindset installing sophisticated technology even in the last steps of textile finishing,” says Philipp Rueedi, CFO at Espritech.

Microplastic pollution is a global challenge across many industries and sectors – one of critical importance being textiles.

A 2021 study by the California Ocean Science Trust and a group of interdisciplinary scientists acknowledges that microfibres from textiles are among the most common microplastic materials found in the marine environment. Every time synthetic clothes are manufactured, worn, washed, or disposed of, they release microplastics into terrestrial and marine environments, including human food chains. Synthetic fibres represent over two-thirds (69%) of all materials used in textiles, a proportion that is expected to rise to 73% by 2030. The production of synthetic fibres has fuelled a 40-year trend of increased per capita clothing consumption.

Global textile consumption has become:

• more reliant on non-renewable resources,
• less biodegradable, and
• increasingly prone to releasing microplastics.

The increased consumption is also discretionary, driven by consumer desire and remains unchecked. Thus, the long-term trend in the textile industry parallels the intentional addition of microplastics to products such as cosmetics. The contrast is that the European Chemicals Agency (ECHA) has recommended such intentional additions be restricted, whereas the over-consumption of synthetic fibres continues unchecked. One way for the EU to account for and mitigate microplastic pollution is through an EU-backed methodology measuring and reporting microplastic emissions, so that consumers and procurement officers have the information needed to minimise microplastic pollution resulting from their purchasing decisions.

There is a critical opportunity to address microplastic pollution in the fashion textile industry through the EU Product Environmental Footprint (PEF) methodology. To meet the environmental objectives of the Circular Economy Action Plan, the EU is proposing that companies substantiate their products’ environmental credentials using this harmonised methodology. However, microplastic pollution is not accounted for in the PEF methodology. This omission has the effect of assigning a zero score to microplastic pollution and would undermine the efforts of the European Green Deal, which aim “to address the unintentional release of microplastics in the environment.”

The incorporation of microplastic pollution as an indicator would increase the legitimacy of the PEF method as well as better inform consumer purchasing decisions, especially as the European Green Deal seeks to “further develop and harmonise methods for measuring unintentionally released microplastics, especially from tyres and textiles, and delivering harmonised data on microplastics concentrations in seawater.”

Whilst we continue to learn about the damage of microplastics and there is new knowledge emerging on the toxic impacts along the food chain, there is sufficient information on the rate of microplastic leakage into the environment to implement a basic, inventory level indicator in the PEF now. This is consistent with the recommendations of a review of microplastic pollution originating from the life cycle of apparel and home textiles. There are precedents in PEF for basic level (e.g., ‘resource use, fossils’) and largely untested (e.g. land occupation and toxicity indicators) indicators, and therefore an opportunity for the EU to promote research and development in the measurement and modelling of microplastic pollution by including such emissions in the PEF methodology. For such an indicator, the long and complex supply chains of the apparel and footwear industry would be a test case with high-impact and a global reach.

The National Council of Textile Organizations (NCTO), representing the full spectrum of U.S. textiles, from fiber through finished sewn products, released an illuminating video and social media campaign detailing the heroic efforts of U.S. textile manufacturers to supply desperately needed medical personal protective equipment (PPE) at the height of the COVID-19 pandemic. The video features interviews with healthcare workers who confronted a once-in-a-generation health crisis and American textile and apparel executives, who came together to manufacture lifesaving PPE as the pandemic intensified and, once again in 2021, when President Biden issued a call to deliver 20 million American-made face masks for underserved communities in 60 days.

To view the video, click here.

Milliken & Company and American & Efird (A&E) hosted United States Trade Representative (USTR) Ambassador Katherine Tai in two separate visits to the companies’ state-of-the-art textile manufacturing facilities, marking an unprecedented visit to the heart of the U.S. textile industry in the Carolinas by the nation’s top trade chief.

Ambassador Tai’s visit comes at a pivotal time for the U.S. textile supply chain, which produced $64 billion in output in 2020 and employed nearly 530,000 workers. The industry has been at the forefront of a domestic production chain manufacturing over a billion personal protective equipment (PPE) items during the COVID-19 pandemic.

The Ambassador’s visit to Milliken included a tour of the company’s Magnolia plant in Blacksburg, S.C., and a roundtable discussion highlighting the important role women contribute to textiles, the critical need for policies supporting a domestic supply chain, and the significant impact of the sector to the U.S. economy. Milliken is one of the largest textile companies in the U.S., employing more than 6,000 associates domestically and an additional 1,350 associates globally. Milliken’s Textile Business alone employs 2,500 people across eight counties in South Carolina and is the fourth largest manufacturing employer in the Upstate.

On the second leg of her trip, Ambassador Tai visited American & Efird’s manufacturing facility in Mount Holly, N.C. American & Efird operates as part of Elevate Textiles and its global portfolio of advanced products and distinguished textile brands, including A&E, Burlington, Cone Denim, Gütermann and Safety Components, and representing more than 500 years of textile manufacturing knowledge.

During the visit, U.S. textile executives spanning the fiber, yarn, fabric, and finished product textile and apparel industry participated in a roundtable with the Ambassador at which they discussed the competitiveness of the domestic industry, outlined priority issues in Washington, such as the importance of the Western Hemisphere co-production chain and ways to jointly support domestic supply chains through Buy American and Berry Amendment policies that help onshore production, spur investment, maintain the safety and security of our armed forces and generate new jobs.

The REACH4texiles project just kicked off. Funded by the European Commission, it aims at exploring solutions for fair and effective market surveillance on textile products.

Every year, about 28 billion of garments circulate across Europe, 80% of which are imported from outside the EU and its jurisdiction.
 
Inevitably, such huge volumes pose enormous challenges for market surveillance authorities which are called to ensure that uncompliant dangerous products are kept away from the EU citizens.

The European Union has the world most comprehensive chemical legislation which is set to protect consumers, the environment and, theoretically, even the competitiveness  of the business.

Such EU chemical legislation evolves constantly, increasing scope and ambition. New restrictions impact authorities and sectors like the European textile value chain and generate new costs for all actors.

Evidence suggests that such advanced regulatory framework is not completed with an equally advanced or effective EU-wide control system capable of ensuring compliance, especially in the case of imported products.

The REACH4texiles project aims at exploring solutions for fair and effective market surveillance on textile products; it pools together the key actors to address three objectives:

• Keep non-compliant products away from the single market.
• Increase skills and knowledge.
• Support a Network addressing chemicals in textiles and applying the EU regulation 2019/1020

The 2 years project will share best practices, identify efficient approaches against non-compliant products, offer training and support for a more effective surveillance and for level playing field.

The project welcomes collaboration with concerned authorities across the EU Member States.

Details:

A well-functioning EU market surveillance system is an essential prerequisite to protect citizen, the environment and competitiveness of responsible business. When it comes to textiles, the broad range of products, the large set of REACH subjected chemicals used in textiles as well as industrial strategies like fast fashion make this a challenging task.

Challenges may include lack of resources, difficulties in identifying higher risk products, cost and management of chemical tests, lack of test methods and knowledge of best practices. These challenges are yet likely to increase with the upcoming REACH restrictions and the growth of e-commerce.

Because of this, products that do not comply with REACH regulations encounter today little or no barriers to enter the market. This creates not only a health risk for Europeans but also undermines the competitivity of responsible businesses that take all necessary measures to comply with these regulations.

Addressing the challenges requires more knowledge at market surveillance and stronger collaboration between these authorities, the textile and clothing industry and testing laboratories. More knowledge about the identification of risk baring textile products and REACH chemicals likely to be used in these products, suitable test methods and strategies such as fast screening on REACH chemicals, trustworthiness of labels, etc can increase the effectiveness of market surveillance considerably.

The REACH4Textiles first objective (keep non-compliant products away from the EU Market) will be pursued by increasing knowledge on market surveillance functioning by and working on a risk-based approach to identify products at higher risk.

The second objective supports a network to address the specificities of chemicals in textiles with market surveillance authorities and involving other relevant stakeholders. The third objective focuses on sharing knowledge with market surveillance actors on textile products and suitable test methodologies.

Supported by the European Commission DG Growth, the project team is coordinated by the Belgian test and research center Centexbel and include the European Textiles and Apparel industry confederation, EURATEX, the German national textile and fashion association Textile und Mode, t+m, the Italian association Tessile e Salute. Several other European industry associations and national authorities are welcomed to become involved through the project activities.   

The European textile and apparel industry welcomes the organisation of the EU-US Summit in Brussels, and hopes that political leaders will launch a new era of closer cooperation across the Atlantic. Both the Covid19 pandemic and recent geopolitical tensions call for global solutions; the EU and the US should take a leadership role in developing that new global framework.

EU-US trade in textiles and apparel have dropped by nearly 20% in 2020 (just under €6 bln), while imports from other countries, in particular China, have increased spectacularly (+45% into the EU). At the same time, global supply chains came under pressure, and access to certain raw materials for the industry became difficult and costly.

Against this background, EURATEX does not call for protectionism, but a better functioning of global supply chains, with common rules which are applied by all. The EU and US authorities should put their full influence to establish a level playing field for our industry across the globe, promoting environmental and social standards. Sustainable and circular textiles should become the norm, thus contributing to a greener planet and creating high quality jobs.  

At bilateral level, the EU and US should resume their work on mutual recognition of standards and certification procedures, thus saving considerable costs for our companies while maintaining the highest safety standards. Custom procedures can be simplified on both sides, and joint research, e.g. in smart textiles, should be promoted.

EURATEX welcomes the recent progress in provisionally eliminating additional duties on several American and European products due to the Airbus-Boeing trade dispute. It is a very positive sign that EURATEX would like to highlight in a particularly difficult context for the textile and clothing industry at European, American and even global levels. EURATEX calls on both US and EU institutions to eliminate such duties permanently and build on a common positive agenda for the benefit of EU and US companies and consumers.

EURATEX Director General Dirk Vantyghem commented: "Both the EU and US are developing a new business model for their industry. We should make sure these models can complement and reinforce each other. If not, we risk losing global leadership, not just in terms of market share but also in terms of values and standards."