From the Sector

The Karl Mayer Group is reducing its ecological footprint when it comes to energy utilisation: The Group's largest photovoltaic system to date has just been installed at its headquarters in Obertshausen.

Following the construction of a stable substructure, the first photovoltaic elements were installed on the roof of the assembly hall in Obertshausen on 16 February 2024. This will be followed by the step-by-step conversion of other roofs. If everything goes according to plan, around 6,000 modules will have been installed on an area of approx. 12,000 m² and over 60,000 metres of cable laid by the middle of the year.

"With a total output of 2.4 MWp, we will be able to generate over 35% of the total electricity consumption at the site ourselves," explains Michael Sustelo, Head of Facility Management at the Karl Mayer Group.

SHIMA SEIKI ITALIA S.p.A., Italian subsidiary of leading Japanese computerized knitting solutions provider SHIMA SEIKI MFG., LTD., will exhibit at the 94th edition of the Pitti Immagine Filati exhibition in Florence, Italy (24th-26th January 2024). It will exhibit as part of the CustomEasy section, which involves the concept of Fashion at Work and explores customization in the presence of textile machinery and design software, represented in part by SHIMA SEIKI's lineup of WHOLEGARMENT® knitting machines and APEXFiz® design software.

The new SWG-XR® flagship machine features 4 needle beds for all-needle knitting of high quality WHOLEGARMENT® products using the company's original SlideNeedle™, in addition to a re-designed sinker system and a compact, light-weight carriage featuring 4 systems as well as auto yarn carriers. All contribute to increased productivity of more than 25% over the previous MACH2®XS machine, as well as increased product range using a wider variety of yarn for supporting knits for all seasons, and higher quality for knitting beautiful fabrics and silhouettes; even items that were impossible to knit with the MACH2® series, including punch-lace patterns, variable stitch knitting and intarsia knitting. Setting new standards for the next generation of waste-free, sustainable WHOLEGARMENT® knitting, SWG-XR® at Pitti Filati will be shown in 15L and 18L as well as a prototype machine in 22L.

APEXFiz® subscription-based design software supports 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. By replacing physical samples, virtual samples reduce time, cost and material that otherwise go to waste.

The product planning capability of APEXFiz® is enhanced by several web services featured as part of the SHIMA SEIKI Online Services (SHIMA online) web platform. These include SHIMA Datamall™ digital content web service that allows users to search, browse and purchase a variety of useful data for streamlining the planning and production of fashion items, as well as the recently renewed yarnbank® digital yarn sourcing web service that offers digitized yarn data by yarn companies from around the world for download and use in virtual sampling. SHIMANAVI® e-learning system is also part of the online platform.

Monforts' new Montex 8500 stenter line was recently installed at Curt Bauer’s plant in Aue in Germany.

Curt Bauer has been in continuous operation for 150 years, beginning as a weaving mill in Aue in the Ore Mountains region of Saxony back in 1882. Today, with 120 employees, the company has an annual production of 2.2 million metres of fabric and specialises in three key fields – home textiles, special damask fabrics for West African garments and technical textiles.

A first Montex stenter was installed by Monforts at the Aue plant in 2003 and an older machine from a third party supplier was also still in operation prior to the latest upgrade.
“The replacement of our older existing stenter, which was installed in 1985, was long overdue,” explains Gert Bauer. “It had a maximum working width of 2.2 metres and we were looking to both increase productivity and reduce energy requirements.”

As a consequence, the company opted for a new Montex 8500 line with a working width of 3.2 metres equipped with the MonforClean heat recovery and exhaust air purification system. The Montex stenter remains unmatched in terms of its robustness and long service life and with MonforClean technology, the waste heat from the drying process is used to pre-heat the drying air. This results in a radical reduction in the conventional heat supply required, compared to full gas and thermal oil heating. Overall energy savings of up to 40% can now be achieved compared to conventional stenters.

The first challenge at the Aue plant was how to fit the significantly larger machine into the available space without restricting the area required for docking operations.

The special multi-level configuration that Monforts designers and Curt Bauer’s team devised in order to meet these requirements involved raising all of the line’s drying zones – with a combined length of over 28 metres – on scaffolding platforms, to enable the ground floor space below them to continue to be fully utilised.

The next challenge involved configuring the MonforClean system without having to make any costly changes to the roofing structure. This, Gert Bauer observes, demanded “millimetre precision”.

With the new line now fully operational, the savings it is providing have yet to be fully calculated.

This year’s edition of ITMA ASIA + CITME proved to be a success for the exhibiting VDMA member companies. Measured by booked square metres, Germany had the largest contingent, among the foreign exhibitors. More than 40 VDMA member companies were exhibiting their innovative products in Shanghai.

Dr. Janpeter Horn, chairman of the VDMA Textile Machinery Association noted: “Although facing a difficult market situation, this year’s edition of ITMA ASIA + CITME has exceeded the expectations, both in terms of the number of visitors and the quality of the talks. The significant number of foreign visitors to the fair was particularly pleasing.”

Solutions were demonstrated for more sustainable textile productions by most of the exhibitors, and here the VDMA members presented their technologies for saving water, energy and raw materials under the heading “Smart technologies for green textile production.”  

Dr. Uwe Rondé, CEO, Saurer Intelligent Technology AG explained: “Saurer is satisfied with both the number of visitors and the quality of the discussions. Our booth was full from morning to evening with customers focused on latest technologies within the three mega trends: recycling, automation and digitalisation. Although machine utilisation in the spinning mills is still well below average, people are already gathering information and thinking about what to invest in once the market recovers.”

Benjamin Reiners, owner of Reiners + Fürst stated: „This year’s ITMA ASIA + CITME has exceeded our expectations by far. Especially the first day - a Sunday - has brought many high-quality customers and exclusively decision makers to our booth. We estimate about 20% international customers mainly from Bangladesh, Egypt, India, Iran, Pakistan, Uzbekistan and Vietnam. All customers agreed that the market situation at the moment is difficult, capacity usage is between 50-75% in the ring spinning sector and improvement is expected not before the 2nd half of 2024. Nevertheless the general spirit is very positive.“

“This ITMA ASIA was a great success for Trützschler. We welcomed a large number of Chinese visitors to our booth, as well as a significant number of interested international visitors”, said Dr. Bettina Temath, Head of Global Marketing Trützschler Group SE.

Georg Stausberg, CEO of the polymer processing solutions division and chief sustainability officer of the Oerlikon Group stated: „We can look back on a successful show where we were able to meet many of our customers not only from China, but also from Pakistan, India and Indonesia, for example.”

“A very well-attended trade fair, with interesting discussions, great innovative topics, in line with the modern and rapidly developing China" noted Wolfgang Schöffl, head of product line weaving machines and member of the extended management, Lindauer Dornier.

The VDMA Textile Machinery Association and VDMA China were present at the fair, to support the members e.g. with regard to IPR. With the help of a VDMA expert and a contracted law firm, the member company Sahm submitted a complaint application for patent infringement disputes during the exhibition to the onsite IPR office. Both parties, Sahm, and the Chinese company, that used patented design without permission reached an agreement: The Chinese company had to stop displaying functions and designs involving patent infringement on site which meant the removal of some structural parts and the covering of key components protected by patent protection.

Dr. Harald Weber, managing director of VDMA Textile Machinery concluded: “Asia, and China in particular, represent the primary foreign markets for the VDMA member companies in the sector. The Chinese market is the main destination for their exports. Other major export destinations in Asia include India, Pakistan, Bangladesh and Uzbekistan. ITMA ASIA + CITME provides a unique platform to showcase technologies for customers directly in Asia. The VDMA member companies are looking forward to the coming edition of the fair from 14 to 18 October 2024 in Shanghai.”

The latest survey of VDMA members' subsidiaries in China gives reason to hope that the economic situation in the Chinese textile industry could also improve significantly in the second half of the year. In addition, European textile machinery manufacturers are urged to be present on the most important market and at the trade fair and to offer Asian customers most advanced technology for their demanding challenges.

Lectra will now directly manage the production of its cutting equipment manufactured in China, primarily dedicated to its Asian customers. The Suzhou site, located to the west of Shanghai, will thus benefit from the standards of operational excellence already implemented by Lectra at its two other plants in Bordeaux-Cestas, France, and Tolland, USA.

Lectra's teams have over 35 years’ experience in the Asia-Pacific region, which in 2022 generated 25% of the Group's revenues.

Since the acquisition of its competitor, Gerber Technology, in 2021, Lectra had been relying on a plant belonging to Dutch group VDL Groep (VDL), to manufacture Gerber-brand multi-ply cutters and spreaders.

For its industrial activities, Lectra aimed to adopt the same standards of operational excellence in China as those currently in effect at its Bordeaux-Cestas and Tolland sites. The Group therefore created a new subsidiary, Suzhou Lectra Equipment Manufacturing Co. Ltd., to take over from subcontractor VDL as of December 1, 2023.

Following the takeover of in-house production at the Tolland site in October 2022, the creation of the Suzhou Lectra Equipment Manufacturing Co. Ltd. subsidiary marks a new milestone in the deployment of Lectra's industrial excellence strategy on a global scale. The Group intends to give priority to regional industrial production, which is beneficial to the local economy.

Santoni Shanghai Knitting Machinery Co., Ltd. announces that it has received regulatory approval from Chinese authorities for its proposed acquisition of Terrot GmbH, a manufacturer of circular knitting machines in Germany.

The acquisition represents a pivotal step in Santoni's strategy to advance the circular knitting machine industry. The integration of Terrot into the Santoni ecosystem is projected to increase Santoni's production capacity and boost its market share, and in conjunction with other strategic objectives, firmly solidify Santoni's position as the leading manufacturer in the industry, with unrivaled scale, depth of innovation and expertise.

Seeking to meet rising demand for high-end circular knitting products, Santoni has pursued an Ecosystem Strategy in recent years, aiming to unify a highly fragmented industry and enhance innovation, sustainability and digitalization to more effectively meet market needs. The deployment of both parties' latest innovation practices, textile automation offerings, integrated enterprise services, C2M solutions, and a platform for designers "Materialliance", will allow Santoni Shanghai and Terrot to connect and bridge demand and offer of circular knitted products.

By incorporating Terrot's offerings, particularly in the double jersey and jacquard sector, Santoni stands to gain a competitive edge in offering machines known for their performance, low maintenance, and cost-effectiveness. Highlighting this shift is Terrot's UCC 572-T, a transfer jacquard machine for sports and leisurewear.

Following the acquisition, Terrot will continue to operate under the leadership of managing directors Robert W. Czajkowski and Dirk Lange. Santoni plans to maintain Terrot’s headquarters in Chemnitz, Germany, along with its facilities, brands, and practices.

Heberlein, founded in 1835, successfully completed the sale of its business on 31^st of October 2023. The new joint ownership comprises the company’s management, alongside industry expert Daniel Lippuner
and the Renaissance investment foundation. From November 1, 2023, the company will operate under the name "Heberlein Technology AG".

The owners are committed to investing in the long-term success of a business that already combines traditional values with innovative power. The brand is known for its high level of expertise, as well as its tailor-made solutions for the textile business. As the world's leading supplier of jets for synthetic yarns, Heberlein develops, produces, and distributes key components for the man-made fibre industry. Around 80 employees and an efficient infrastructure in Wattwil, Switzerland, ensure that international customers can continue to rely on quality and reliability.

The Renaissance investment foundation was established by pension funds, for pension funds, and has been investing in unlisted Swiss SMEs for over 20 years.

Under the new ownership, the Heberlein business will continue unchanged at the current location in Wattwil with the current management and all current employees. The board of directors and management of Heberlein AG welcome this solution and are convinced that the existence of the company and its traditions will now be secured in the long term and that it will continue to develop successfully – positive news also for the business location of Toggenburg and the canton of St. Gallen.

Martin Zuercher, CEO of Heberlein, says of the transaction: "With this sale, we are opening a new, positive chapter in the company's long history. With the Renaissance investment foundation, we found an owner who is focused on long-term success. Together with the energetic management team, I look forward to continuing to make a significant contribution to Heberlein's success in the future."

SHIMA SEIKI MFG., LTD. of Wakayama, Japan will participate in the A+A 2023—Safety, Security and Health at Work International Trade Fair in Düsseldorf, Germany (24th-27th October 2023). On display will be the company's latest safety-related technology through its new SPG®-R pile glove knitting machine and the prototype SFG®-R next-generation glove knitting machine. Each of these machines drew attention at SHIMA SEIKI's booth at the International Textile Machinery (ITMA 2023) Exhibition in Milan.

SHIMA SEIKI's original SPG®, developed in 1979 as the world’s first automatic glove knitting machine to produce seamless pile-knitted gloves, is now reborn as a next-generation model. Pile gloves feature special traits that include cushioning, shock-reduction and thermal insulation and cold protection, making them popular especially in the field of industrial safety. Now, SPG® is redesigned from the ground up and re-introduced as the SPG®-R. The new SPG®-R features a new moveable sinker system with selectable loop presser function. Combined with a new belt-driven carriage it allows SPG® to provide efficient and reliable production of fashionable, high-quality pile gloves. Shown in 7 gauge at A+A, SPG®-R surpasses the previous generation with pioneering technology, improved capability and reliable productivity.

SHIMA SEIKI's original product on which the company was founded was the fully automated seamless glove knitting machine. While the original model evolved to become the current SFG® series, SFG®-R exhibited at A+A is its spiritual successor. With a new sinker system, a belt-driven 2-cam carriage and auto yarn carriers SFG®-R is a completely new machine for knitting gloves that conform better to the shape of the hand for improved fit. Furthermore its greater design potential offers users the opportunity to break out of the work glove market and into the fashion market. SFG®-R is shown as a prototype next-generation model in 12 gauge at A+A.

Also demonstrated will be SHIMA SEIKI's APEXFiz® design software. The importance of design software is made even more significant by the new patterning capabilities of SPG®-R and SFG®-R. Both machines now feature increased design potential that allow each of their products—pile gloves and work gloves, respectively—to expand their market into fashion. APEXFiz® is available for developing these designs. Furthermore virtual sampling on APEXFiz® is especially effective in streamlining the production process. Ultra-realistic simulation capability allows the use of virtual samples for evaluating design variations without producing actual samples for each variation, thereby minimizing the time, cost and resources normally required with sample-making, supporting smart, speedy and sustainable production.

Founded in 2013, NOPINZ is a UK-based manufacturer of clothing for cyclists and triathletes. The company's first product was the ‘SpeedPocket’, a product that allows competitors to attach their race numbers more easily (and with ‘no pins’) while improving the all-important aerodynamics. Soon recognising the customer demand for premade attire with incorporated number pockets, the company embarked on a mission to manufacture these new product lines itself. Today, NOPINZ boasts a diverse portfolio, with 60% of its products made in-house, catering to a growing customer base across the UK and international markets. NOPINZ creates speed suits for some of the world’s top cycling teams, as well as competitive amateurs.

NOPINZ places a strong emphasis on sustainability and is committed to minimising its environmental impact. Using a microfactory approach gives better oversight and control of the manufacturing process, including sourcing materials sustainably and locally where possible, reducing transportation, and improving access to recycling. “Our ‘zero to landfill’ policy, means that we reduce our wastage where possible and either recycle or donate excess product to charity,” Blake adds. “We hope to become a B-Corp company in the future.”

“We tested out a few printers, before we ultimately settled on Mimaki,” Blake Pond, the founder of NOPINZ explained. Now the company’s line-up entirely consists of Mimaki’s textile dye sublimation solutions.
“During our search we prioritised the ability to produce fluorescence and accurately replicate colours. Customers often come to us with existing kit made by other manufacturers, which they want to match, so accurately replicating colour is extremely important. And even without existing kit, customers occasionally ask for specific pantone colours. When it comes to cycling kit, colour is often pivotal when considering where to buy from.”

As two flagship dye sublimation printers, both the TS300P-1800 and TS55-1800 are equipped to print on the various technical fabrics that are needed for cycling attire and faithfully reproduce colours to meet customer expectations.

Stahl, a leading provider of coating technologies for flexible substrates, has been awarded a Platinum rating by the sustainability rating agency EcoVadis for the second consecutive year. For the 2023 EcoVadis assessment, Stahl’s rating increased by three points compared to its 2022 score, reflecting the company’s improved performance in the area of labour and human rights.

Progress in the Labour & Human Rights category
The 2023 EcoVadis assessment revealed the progress Stahl is making in the Labour & Human Rights category, where Stahl scored 90 out of a possible 100 points. This reflects the company's recent work to improve its health and safety management systems. In particular, the majority of Stahl’s global manufacturing sites are now ISO 45001 certified and more than 94% are ISO 14001 certified. Stahl has also taken steps to improve its approach to employee career development and well-being. These include the creation of an individual career plan for all employees and the introduction of a new company-wide employee satisfaction survey.
 
Stahl moves forward with 2030 ESG ambitions
Stahl has set a 2030 target to maintain its EcoVadis Platinum rating by working closely with its value chain partners to help them reduce their impact. In 2022, 83% of Stahl’s total spend on raw materials was sourced from EcoVadis-rated suppliers.

EcoVadis is a globally recognised, evidence-based rating platform that assesses the performance of more than 90,000 organisations against key sustainability criteria across four categories: Environment, Labour & Human Rights, Ethics and Sustainable Procurement. For the 2023 EcoVadis assessment, Stahl received an overall score of 80 out of 100, up from 77 in 2022. This score indicates an advanced level of sustainability maturity and ensures that Stahl retains its Platinum rating. This is awarded to the top 1% of companies assessed by EcoVadis. Stahl achieved its first Platinum rating in 2022, having undergone its first EcoVadis assessment in 2015.