From the Sector

Vision and technology are the key ingredients of a ground-breaking school blazer that is showing how businesses can move to a circular textiles economy.  
 
While many brands are grappling with the complexities of inevitable legislation and engrained business models, leading school uniform producer, David Luke, has launched a fully recyclable ‘circular’ school blazer that is designed to be recycled through Project Re:claim, the world’s first commercial-scale polyester recycling plant.
 
Project Re:claim is a joint venture between the UK’s largest charity textile collector, The Salvation Army, and leading circularity specialists Project Plan B. The plant opened in the UK in January 2024, and presents huge opportunities for brands to transition to textile-to-textile manufacturing models.
 
David Luke’s circular blazer has been introduced to the brand’s successful Eco-uniform range which has sold over 1.7 million Eco-blazers in the last decade. Up until 2023, David Luke’s Eco-blazer, like many recycled garments, has been made from recycled plastic bottles. But the company has been working with Tim Cross, CEO of Project Plan B and the Circular Textiles Foundation, to bring the 100% recyclable blazer to market.
 
Tim Cross said: “David Luke has grasped the opportunity to embed 100% recyclable and 100% recycled garments into their range, starting with the school blazer. We now have the technology to enable their blazers to be recycled without any separation of the garment, making it an efficient recycling process. The team at David Luke has worked tirelessly with their manufacturers to create a blazer that does not compromise on design or quality, and yet is much kinder to the environment.”
 
Every detail from the lining, buttons and zips to the inter-linings and adhesives, has been re-thought and re-designed to meet the demands of an everyday school blazer and to recycle the garment once it reaches its end-of-life. Up until now, when the blazers have eventually been handed down to siblings, or given to the local charity shop, there had been no end-of-life solution for polyester garments apart from incineration. Now, Project Re:claim can recycle the blazer to produce polyester pellets, which are then spun into yarn to be used for future David Luke circular blazers.
 
Cross continues: “David Luke has the vision to create a fully circular range, and we have the potential to supply recycled content. The possibilities are infinite in terms of the future of garment design and manufacturing.”
 
Kathryn Shuttleworth, Chief Executive of David Luke, said: “It is a natural next step for us to transition to a textile-to-textile model. We have been producing garments using recycled plastic bottles for 15 years, but we have always had an eye on developments in textile recycling and solutions for end-of-life garments.”
 
In 2020, David Luke was awarded the Queen’s award for Enterprise for Sustainable Development and in January 2023 the David Luke circular blazer achieved Circular Foundation Textile certification.
 
Shuttleworth added: “Our focus will always be on those essential ingredients for parents and children - style, durability and affordability. But we have a responsibility to change our business model to better protect children’s future and the environment. It has become our obsession to make uniforms that meet our customers’ demands. We are really excited about the future as we continue to develop our range.”
 
Majonne Frost, Head of Environment and Sustainability for Salvation Army Trading Company, said: “Our vision is to enable companies to produce uniforms, corporate wear, fashion garments and textile ranges using recycled polyester.  We have the infrastructure to collect donations at scale and we now need companies to step up. This is an opportunity for companies to make a commitment to significantly reduce their environmental impact, and David Luke are showing us how that is possible.”

Juki America and Coloreel revealed a partnership that will extend Coloreel’s thread dyeing technology to the sewing industry. With Coloreel, Juki sewing machines can now access millions of precise colors in real time.

Juki’s distributors will get exclusive rights to market and sell Coloreel for sewing machines within North and South America. The first official installation of Coloreel paired with a Juki sewing machine will be at FABRIC Incubator in Arizona, USA, a fashion incubator and garment manufacturer that supports up-and-coming designers.

Cascale, a non-profit alliance for driving impact in consumer goods (formerly the Sustainable Apparel Coalition), announces Colin Browne as its new Chief Executive Officer, effective May 1, 2024.

Browne previously served as Interim CEO and Chief Operating Officer of Under Armour, a Cascale member. During his tenure at Under Armour, Browne oversaw sustainability efforts and, in addition, led significant transformations across supply chain, go-to-market and technology. In 2023, the company shared achievements related to its environmental footprint, product circularity, and renewable energy goals – some accomplished with Cascale’s Higg Index suite of tools.

Prior to joining Under Armour, Browne was managing director of Asia Sourcing for VF Corporation, a Cascale member that includes The North Face, Timberland, Vans, and Smartwool brands. In addition to his experience leading brands, Browne also spent four years running manufacturing plants in Thailand and began his career at Bally Shoe factories in the UK. He has lived and worked in the UK, South Korea, mainland China, the Philippines, Thailand, Hong Kong SAR, and the USA; his international experience and localized approach underscore his commitment to Diversity, Equity, and Inclusion (DEI) both in and outside of the workplace. Browne also served as the Chairman of the American Apparel and Footwear Association and was on the board of the World Federation of Sporting Goods Industries. As a member of the Worldly Board, the leader in environmental and social impact data for the apparel and footwear industry and the exclusive platform for Cascale’s Higg Index tools, Browne will ensure a unified approach to advancing sustainability initiatives across both organizations.

During his first 100 days with Cascale, Browne will connect with the organization’s 300+ members across the value chain, emphasizing manufacturer engagement and relationship building. He will also engage Cascale’s broader ecosystem of stakeholders including NGOs, governments, and academia. Browne is personally committed to Cascale’s vision to lead the consumer goods industry to combat climate change, foster decent work for all, and build a nature-positive future.

UK-based textile testing solutions provider James Heal has launched two new instruments in its tensile and compression testing range, marking 25 years of innovation since their first Titan universal testing machine was developed in 1999.

Having seen sustained growth in the market for personal protective equipment (PPE), particularly safety workwear, equipment and footwear, James Heal designed the Titan 25 to meet demand for quality testing products that require higher capacity tests. In addition, the company has experienced increasing demand in testing solutions for wider sporting, industrial and transportation applications, which also influenced the decision to develop higher capacity test instrumentation.

The new Titan 25 is the highest capacity universal testing machine to join the range capable of tests up to 25kN, while the 10kN Titan 10 has been newly refined. The new instruments offer efficiencies through automation, quick change connections for tooling with compatibility across the range, upgraded software, plus enhanced safety features.

These dual column instruments enable testing on larger specimens across a wide range of tensile and compression tests. Load cells from 100N to 25kN allow testing to as low as 2N giving laboratories maximum flexibility and return for their investment.

Simple to use, the new Titan testers have over 750 pre-loaded standard procedures in the TestWise software, with the option for users to customise and save their own standards. The software automatically sets parameters for each selected test, reducing set up time and eliminating user error.

Kornit Digital LTD. will display its digital fabric and integrated workflow portfolio at Texprocess 2024, being held April 23-26.

Kornit Digital will feature a view into the end-to-end, fabric manufacturing ecosystem – allowing for production of any fabric and any design for any purpose. The centerpiece is Kornit Presto MAX, transforming the digital world of fabric printing with an ability to print on any fabric type – from cotton and polyester to denim and leather. Built on the promise of sustainability, Presto MAX reduces both water usage and waste. The system is the world’s first offering to print white ink on colored fabrics alongside neon to extend the color gamut by as much as 30 percent. Kornit’s new Vivido inks additionally offers dark black pigments.

Additionally featured is the KornitX Global Fulfillment Network, a solution designed to optimize operational efficiency, eliminate supply chain bottlenecks, and ensure products are readily available to meet customer demands. The solution connects brands, retailers, and digital platforms to a high-quality production network – providing rapid replenishment and trend adaptability for direct-to-fabric production. Pixel-to-parcel monitoring and control fully integrates the end-to-end production workflow for a seamless experience. The solution based on Kornit’s MAX technology enables brands to maximize margins, boost profitability, and pave the way for a sustainable future in the digital on-demand fashion and textile industry.

Beyond technology demonstrations, Kornit will additionally highlight how MAX technology serves as a vibrant partner platform to drive possibilities across the entire fabric printing and processing chain. Key partners highlighted include:

• Colortex: Providing fashionable, custom textiles for the footwear industry.
• ZwissTex: Offering quality, sustainable textile solutions for the automotive and clothing sectors.
• Print Logistic: Delivering a full range of services - from printing to worldwide drop-shipping for smooth e-commerce integration.
• CGS: Driving global performance through business applications, enterprise learning and outsourcing services.
• FastSwen: Leveraging Moving Cavity Technology (MCT) to transform textile handling and production efficiency.
• Premier Digital Textiles: Serving as the prime supplier of textiles with extensive warehousing across the US and UK.
• Greentex: Providing highly sustainable, innovative, and customizable fabrics for advanced textile printing.

ACG Kinna Automatic and ACG Nyström – members of TMAS, the Swedish textile machinery association – have delivered the first microfactory for the production of fully finished filter bags to an international filtration industry customer, in cooperation with JUKI Central Europe.

The microfactory’s configuration is based on two separate interconnecting modules – the Smart Filter Line (SFL) and the Filtermaster 2.0. The SFL handles the fabric feeding from rolls and its folding prior to seam construction, which can either be by automatic sewing, welding or with sewing and taping, depending on specifications. Very rapid changeover of the modular seaming methods can be achieved during product changes. The specific size of the now fully-tubular fabric is then precisely cut to size for each individual unit and further folded ready to be fed into the Filtermaster 2.0. The Filtermaster 2.0 then automatically attaches the reinforcement, bottom and snap rings onto the filter tube with a second Juki sewing head on a robotic arm, to form the fully finished filter bag ready for packaging.

Filter bags are employed in a wide range of industrial processes and while they may be largely under the radar as products, they represent a pretty significant percentage of overall technical textiles production.
They are used in foundries, smelters, incinerators, asphalt plants and energy production plants. Other key manufacturing fields – often where dust is generated – include the production of timber, textiles, composites, waste handling and minerals, in addition to chemicals, food production, pharmaceuticals, electronics and agriculture.

As a further example of the scale of the industry and the high volumes of fabrics involved, one supplier has delivered a single order of 30,000 filter bags to be used for flue gas cleaning at a European power plant. The bags can also be anywhere up to twelve metres in length and frequently have to be replaced.

In a move to enhance the global competitiveness of the Turkish apparel industry, the Istanbul Apparel Exporters' Association (IHKIB) has entered into a collaborative agreement with the Worldwide Responsible Accredited Production (WRAP).

IHKIB, representing 80% of Türkiye's apparel exports, aims to facilitate and guide its members in navigating new markets and staying abreast of sectoral developments.
WRAP, a US-based non-profit organization, focuses on promoting safe, lawful, humane, and ethical working conditions within the textile and apparel industry.

Mr. Selcuk Mehmet Kaya, Chairman of the International Relations and Sustainability Committee of IHKIB, and Mr. Avedis Seferian, President and CEO of WRAP, officially inked a collaboration agreement on March 8, 2024, marking a significant step towards fostering business relations between Türkiye and the USA. The agreement focuses on a pilot project developed by IHKIB and WRAP, aiming to identify leading Turkish apparel companies exporting to the USA and encouraging these facilities to attain WRAP certification. In return, WRAP will provide in-person and virtual training at no charge to guide these facilities through the certification process. The project seeks to strengthen business ties between Türkiye and the USA, creating additional opportunities for mutual cooperation between the parties in both countries.

Trotz einiger Insolvenzen ist der Einzelhandelsumsatz mit Schuhen nach ersten Hochrechnungen des BTE Handelsverband Textil Schuhe Lederwaren im letzten Jahr um rund vier Prozent bzw. 480 Mio. Euro auf 11,6 Milliarden Euro (inkl. MwSt.) gestiegen. „Der Umsatz liegt damit allerdings immer noch knapp 1,5 Prozent unter dem Vor-Corona-Niveau von 2019“, berichtete BTE-Geschäftsführer Axel Augustin anlässlich der HDS/L-Pressekonferenz am 4. März im Rahmen der Düsseldorfer Fachmesse SHOES.
 
Überdurchschnittlich abgeschnitten hat im letzten Jahr vor allem der stationäre Schuhhandel. Die Umsätze der Schuhgeschäfte sind nach BTE-Schätzungen um fast acht Prozent gestiegen, liegen aber immer noch etwa sechs Prozent unter 2019. „Wir beobachten allerdings im gesamten Handel große Unterschiede je nach Standort oder Geschäftskonzept“, konstatierte Augustin. „Die Bandbreite reicht von Rekordumsätzen bis zu Geschäftsaufgaben bzw. Insolvenzen wegen der stark gestiegenen Kosten und zu großen Substanzverlusten während der erzwungenen Corona-Schließungen.“
 
Nach Schätzungen des BTE haben 2023 rund 170 Schuhhändler ihre Türen für immer geschlossen – teils wegen Insolvenz, teils freiwillig z.B. wegen fehlender Nachfolger. Aktuell dürften nur noch etwa 2.600 stationäre Schuhspezialisten am Markt aktiv sein. 2013 waren es laut Umsatzsteuerstatistik noch 4.640 Unternehmen.
 
Als größtes Problem nehmen die stationären Schuhhändler derzeit die zunehmende Bürokratie wahr. Auf Rang zwei rangieren die hohen Kostensteigerungen. Oft beklagt wird zudem die Kaufzurückhaltung der Kunden, der zunehmende Wettbewerb mit den eigenen Lieferanten, der Fachkräftemangel sowie ein Attraktivitätsverlust des eigenen Standortes.
 
Umsatz verloren hat im letzten Jahr der Versand- bzw. Onlinehandel.  Er liegt aber wegen des starken Aufschwungs in den Coronajahren 2020 und 2021 nach BTE-Schätzungen rund 40 Prozent über 2019. Augustin: „Wir gehen davon aus, dass der Anteil des Versandhandels am gesamten Schuhmarkt im letzten Jahr bei knapp einem Viertel lag.“
 
Für 2024 sind die Umsatzerwartungen der Schuhhändler sehr verhalten. Laut einer aktuellen BTE-Umfrage rechnet lediglich ein Viertel der Teilnehmer für das laufende Jahr mit einem nennenswerten Umsatzplus. Ein weiteres Viertel sieht sich in etwa auf dem Niveau von 2023, knapp die Hälfte befürchtet dagegen Einbußen von mindesten einem Prozent. „Wir müssen daher 2024 mit weiteren Geschäftsschließungen rechnen“, so Augustin.

The fifth edition of IFCO Istanbul Fashion Connection took place from 7 to 10 February 2024 with a record 38,545 visitors. At IFCO, 545 exhibitors met international trade visitors from 159 countries such as Australia, Canada, Colombia, France, Germany, Kenya, Malaysia, Mexico, Nigeria, Philippines, Saudi Arabia, South Africa, South Korea, Spain, Thailand, UK, USA, United Arab Emirates in a total of 8 halls at the Istanbul Expo Centre. The largest group of foreign visitors came from the Middle East (33.4%), Europe (24%), Asia (23.3%) and North Africa (13.3%). A total of 6% of visitors came from the USA, South America, Australia and Africa.

Divided into clear exhibition areas on a total of 100,000 square metres of exhibition space, brands and manufacturers presented the latest collections from the areas of womenswear, menswear, kidswear, denim, sportswear, evening and wedding wear, lingerie, hosiery, leather and furs.

The next IFCO is planned for 7-9 August 2024.

Fibre Extrusion Technology Limited (FET) has been awarded £50,000 of grant funding to collaborate with the University of Manchester on complex spin pack and spinneret designs. This funding will provide FET with access to the expertise of four universities and the National Physical Laboratory to develop the next generation of machinery.

The grant is awarded by a consortium led by AMPI (The Advanced Machinery and Productivity Institute) and NPL (The National Physical Laboratory). AMPI’s Innovation for Machinery (I4M) programme supports businesses in West Yorkshire and Greater Manchester as part of an overall initiative to drive innovation for the UK’s advanced machinery manufacturers to meet the challenges of developing new technology and entering emerging markets.

In this project, FET will be working with the University of Manchester to conduct computational fluid dynamics (CFD) studies on a number of complex spin pack and spinneret designs. The aim of this work is to identify areas of improvement for FET’s spin packs and spinnerets and to use computer aided designs to develop significantly more efficient versions. The goal is that the research will improve the throughput of FET extrusion systems, thus reducing the amount of polymer lost through inefficient flow paths. This development, in turn, will reduce the environmental impact of synthetic polymer processing.

FET designs, develops, and manufactures extrusion equipment for a range of high value textile material applications worldwide. Established in 1998, FET’s major strength has always been to collaborate with customers in testing, evaluating and developing high value materials with diverse, functional properties. Efficiency and sustainability are key, so enhanced development of spinneret technology will contribute significantly to these objectives.