Denim laundry of the future by Tonello
OBleach is the new ozone, patent-pending process, which “returns to the future” with an authentic, sustainable and cool bleach without hazardous chemicals. This is possible thanks to our All-in-One system by Tonello, a single machine that contains the most recent generation of finishing technologies: ECOfree 2, NoStone®+, UP and Core.
The rollout of OBleach times well with companies that are aligned with 2020 goals in Greenpeace’s #Detox My Fashion campaign, which bans potassium permanganate from the supply chain.
This sophisticated new system allows users to create vintage effects on jeans with lasers that are then transported via a robot and loaded into an ‘all-in-one’ washing machine equipped with ozone bleaching, stone-free abrasion and spray technology for chemical applications, after which the jeans are simply tumble dried.
The way this “denim laundry of the future” works according to Tonello, is that once a pair of ready-made jeans are laser finished on a mannequin, they can be loaded robotically into the front-loading all-in-one machine.
The system saves energy, reducing water and chemical consumption, cutting down processing times and total production costs: respecting the environment, reducing manual labour and protecting the health of operators. The All-in-one system is the perfect symphony of creativity, technology and performance. It has now become a reality with the arrival of ECOfree 2 being added to the already proven NoStone®, Core, and Up.
CORE
Core is a new technology that can be applied to Tonello washing and dyeing machines of various sizes. It is capable of creating uniform or contrasting effects that go beyond fleeting fashions to bring out the full potential of the garment. Core makes it possible also to apply a wide range of products, while considerably reducing consumption.
ECOFREE 2
ECOfree 2 is the latest washing technology using ozone in both the water and the air. This guarantees the best performance on the garment, fewer manual operations and a huge reduction in water and chemical consumption.
NOSTONE®
NoStone® is the new denim-washing system developed by Tonello in collaboration with Levi Strauss & Co. It is designed to overcome the economic, mechanical and environmental limitations of the stone-washing process.
UP
UP patented technology reduces the liquor ratio to unparalleled levels, saving water and energy and making water filling and draining faster. UP is a revolutionary innovation applicable to all existing Tonello machines, including the least recent: Tonello machines do not age, they evolve.
MAYA launches Intelligent Auto Digitizing Embroidery Software
Technology is expanding and computers and software are playing a big role in our current life. Devices are becoming smarter using AI (Artificial intelligence) and latest development in software technology like machine learning and neural networking can make amazing results which lets a computer think like a human brain.
Recently, MAYA has started some projects to involve this smart technology into embroidery field. MAYA has taken the first step to achieve this target by starting a project called iBox (intelligent Box) which can convert an image into embroidery design using AI. iBox can optimize stitch connections almost like an expert designer. The converted design has as less trim as possible and the machine can run the design very smoothly. As we all know, many companies have worked on image into embroidery conversion, but since the quality is the main issue in this field, their conversion result has not been practically workable and it has not satisfied the designers, that is why designers prefer to digitize the design by themselves to create a high quality product, but this is also a very time consuming procedure.
Since the start of iBox project, the quality has been the main concern of MAYA software team. And in Cisma 2019, MAYA introduced the first high quality image into embroidery design conversion device to the world.
iBox contains the hardware and software together as one package, and you will just need a screen or you can even connect it to your TV at home and connect a mouse and enjoy using your creativity to make embroidery designs in few minutes.
iBox is the new generation of digitizing software and users do not need to know so many complicated functions and how to digitize a design and connect the objects, because iBox already knows how to do the job for you. iBox can now convert a design using Satin and Tatami, but MAYA plans to develop this technology and let all range of users be able to use iBox in their business.
“The technology behind this software is the Artificial Intelligence, which is totally a new approach in this field. Though there are a few software brands doing photo to embroidery but results were not practical and good enough to make a designer really happy. Wherein, in this software the result is totally practical offering very good and acceptable quality. For normal embroidery quality is the biggest issue which could be solved with this new software, which is revolutionary. When using software, a designer will take half an hour to make design which earlier used to take 10 hr to complete. We introduced this to the industry for the first time in CISMA and response has been really encouraging,” says Saeed Shekari, Software R&D Director, Maya Embroidery Machine.
iBox has four main below functions:
• Image into embroidery design (no limits in colours)
This is the most time-consuming task if a designer wants to digitize it by current digitizing softwares at the market, but using iBox it is a few minutes task with good quality. The image quality affects the result, so the image should have an acceptable quality. But for other conversions, you can use any photos. The built in editor lets the user edit the photo and special functions designed for layering the image and making the sections overlaps to compensate fabric shifting and thread pull compensation.
• Photo into single coloured designs in three styles (one colour now)
• Photo into cross stitch design (no limits in colours)
• Photo into sequin design (up to 8 colors) as well as flipping sequins
Established in the year 2000 in Zhuji City, Zhejiang Province, China, Zhuji MAYA Electric Appliance Machinery Co., Ltd. is an enterprise specialized in producing computerised multi-head embroidery machines with annual output of more than 4,000 sets high quality machines. Having advanced equipment for manufacturing and inspection as well as excellent work teams, the company commits itself to implementing the total quality control system, introducing new concept of international standard management, and continuously improving the quality of its products.
CISMA 2019 Highlights global sewing machines latest offerings
Lectra unveiled flagship Industry 4.0 Solutions for Asia market
On September 25, witnessed by numerous guests and visitors, the opening ceremony of CISMA 2019, I.E., the top event of the world’s sewing machinery industry was solemnly staged in the South Hall of Shanghai New International Expo Centre, China.
Leaders and guests, such as Zhang Chonghe, the President, and Bu Zhengfa, the former President, of China National Light Industry Council, Cao Xuejun, the Deputy Director of the Consumer Product and Industry Department of the Ministry of Industry and Information Technology, Li Chunmei, the Deputy Director of the Industry Association Bureau of the State – owned Assets Supervision and Administration Commission of the State Council, He Ye, the Vice President of China National Light Industry Council and the Chairman of China Sewing Machinery Association, Li Yuzhong, the Chairman of China Leather Association, Tu Qi, the Vice Chairman of China National Furniture Association, Zhu Xiaohong, the Vice Director of China Home Textile Association, Hachiro Makabe, the Chairman of Japan Sewing Machinery Manufacturers Association, Gunter Veit, the Chairman of VDMA German Garment and Leather Technology Association, Michael McDonald, the Chairman of Sewn Products Equipment & Suppliers of the Americas, together with the Vice Chairman and specially invited Vice Chairman of China Sewing Machinery Association and the representatives of key enterprises in the industry, CISMA 2019 exhibitors, customer representatives and news media, more than 100 persons in total, have attended the opening ceremony.
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- SG Group presented their latest technologies
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- Juki displayed automatic sewing machine range
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Anshuman Dash with Hugo Ho from
H&H and Akesh Awasthi, Sakho Group (L-R)
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- Dhavall Thakkerr from Ketty Apparels with Gordon Chou from Siruba and Murlidhar Shankar Pattar from Mehala Machines India Ltd. Mumbai (L-R)
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- Yuan of Zhuji Maya Electric Appliance Machinery Co., Ltd., Suneet Kharbanda from Kavita Woment Wear and Sanjay Jha, Unix Stitchmachines Pvt. Ltd. (L-R)
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- B. P. Mishra, Vardaan Events Pvt. Ltd., Elgbert from Jack Sewing Machine, Rajeev Ranjan, C.K. Trading and Billy from Jack Sewing Machine (R-L)
The opening ceremony was presided over by Yang Xiaojing, the Vice Chairman of China Sewing Machinery Association. Yang announced the official opening of the ceremony. Later, He Ye, the Chairman of China Sewing Association, delivered a wonderful opening speech. On behalf of China Sewing Machinery Association, she expressed warm welcome and heartfelt thanks to the leaders and friends from home and abroad who attended CISMA 2019.
In the Speech, Chairman, he had summarized the achievements made by China sewing machinery industry since the start of the new round of industrial revolution in terms of aspects such as technology, products, process equipment, talents, market, management by taking smart sewing as the main path for the high quality development of the industry and actively implementing the strategy of strengthening the country by sewing machines.
She pointed out that by virtue of effective resources integration, consensus refining and demand docking, the whole industry has established a number of industrial intelligent sewing alliances across the upstream and downstream industrial chains, constructed the global smart sewing product technology and standard system, innovated and developed a large number of intelligent sewing products with independent intellectual property rights and core technology, explored and tried a variety of “Sewing + internet” operation and service modes, and initially established the industrial ecosystem of IoT-based sewing cloud platform. CISMA also makes unremitting efforts to promote the information publicity and display, trade exchange and cooperation, information and technology communication, linkage between upstream and downstream industries, etc.
She hoped that CISMA would continue to expand services and create value for the industry and the world with a broad mind, and wished us a close cooperation and a win-win achievement in smart sewing. Finally, the leaders and guests from home and abroad come to the stage to cut the ribbon at the opening ceremony of CISMA 2019, marking the start of the splendid CISMA 2019 tour.
After the opening ceremony, the guests, including the superior leaders such as President Zhang Chonghe, former President Bu Zhengfa, Deputy Director Cao Xuejun and Deputy Director Li Chunmei, the main leaders of downstream industry associations of leather, furniture, home textile, etc. as well as the representatives of Japan Sewing Machine Manufacturers Association, German Garment and Leather Technology Association and Sewn Products Equipment & Suppliers of the Americas, visited the booths of various enterprises, accompanied by the leaders of China Sewing Machinery Association such as Chairman He Ye.
The leader of each enterprise introduced its featured intelligent products in detail. Therefore, the show has won high praise from the guests. As agreed by the guests, the high level of automation and intelligentization demonstrated by the sewing machinery industry was shocking, enabling them to fully feel the fantastic integration of science & technology into sewing, the wonderful switching between digital and reality, and the globalization of the industry in smart scenario.
As expressed by the leaders of department such as MIIT and ASASC thought that, judging from the situation of the show, China sewing machinery industry is actively realizing the ambitious goal of smart sewing and smart production, is able to take the lead in realizing the powerful goal of “Made in China 2025,” and is confident in realizing high-quality development. The development of advanced equipment manufacturing industry and the promotion of automatic and intelligent products are the key development directions to be encouraged in China, and will continue to actively support the sewing machinery industry in the future.
Show highlights
With more than 100,000 visitors marking their sturdy presence, China International Sewing Machinery and Accessories Show concluded successfully. The exhibition covered pre-sewing, sewing, and after-sewing equipment, CAD/CAM’s spare parts and accessories, which can cover the whole garment production procedure.
CISMA 2019 exhibition showed first-hand the trends on ‘Intelligent Manufacturing’ and the theme was ‘Smart Sewing Factory – Technologies and Solutions’. Collections of the fair was integrated with innovations of the sewing industry such as the collision and integration of sound, light, electricity, sensor control remote and big data.
Renowned enterprises including SG Group, Typical, Zoje, Jack, Feiyue, Hikari, Maqi, Precious, Duerkopp Adler, Pfaff, Juki, Brother, Pegasus, Yamato, Lectra, Eastman, Gerber Technology, Bullmer, FK Group, showed their cutting edge technology solutions during the show. Intelligent manufacturing was a hot spot for innovation in various industries, which was shown in the exhibition. Morgan Tecnica, Groz- Beckert showed their cutting edge technology solutions.
In modern technology, the sewing machinery is now the original driving force for the development of the RMG industry. Quality and state-of-the-art industrial automated sewing machines improve work productivity and generate more values in production. Technology suppliers presented their updated latest trends which will up gear up them to the modern development in the sewing industry.
Belt and Road Forum for International Cooperation of sewing machinery industry
At CISMA 2019, elites of the sewing machinery industry from various countries and regions in the world gathered in Shanghai to attend the Belt and Road Forum for International Cooperation of the sewing machinery industry. The forum, themed “Establishing a New ‘Belt and Road’ Corporation Mechanism for Sewing Machinery Industry,” was hosted by China Sewing Machinery Association and organised by the Market Committee of the Association. He Ye, the Vice President of China National Light Industry Council and the Chairman of China Sewing Machinery Association, Hua Shan, the Executive Vice President of the Industrial Economy Research Institute of China National Textile and Apparel Council, Hachiro Makabe, the Chairman and the former Chairman of Sewn Products Equipment & Suppliers of the Americas, Elgar Straub, the Executive President of German Garment and Leather Technology Association, Lin Yongchang, the Chairman of Xinbei City Stitching Machine Commercial Guild, and Jiang Fengyi, the Chairman of Hong Kong Sewing Machinery Association attended the forum. In all, more than 100 people, including exhibitors, visitors and representatives of various associations attended the forum which was presided over by Yang Xiaojing, Vice Chairman of China Sewing Machinery Association and the Director of the Market Committee.
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- Kundan Kumar Gupta with Douglas Zhu from Zoje Sewing Machine Co. Ltd.
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- Ronny Timuari with Manpreet Singh Waila, INL International Technology Pte Ltd. (L-R)
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- Shivalingappa N.G from Loika Global Pvt. Ltd. with his team
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- Piyush Khurana, Kay Tee Lon Impex Pvt. Ltd., Chen from Promaker and Nitin Soni, Dolphin Jingwei Technologies (L-R)
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- Paresh Lathiya (R), and Dilip Lathiya (L) from Sinsim Liberty with his principal from China
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- Alex J. with Manoj Kumar Gupta from Typical International Corporation
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- Steven with Rahul Prakash from Ningbo Supreme Electronic Machinery (R-L)
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- Murari Lal, Baba Textile Machinery with Chen from Yuemei and Subhash Dawar from Alliance Embroidery Machine (L-R)
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- Embroidery machine agents from India at Beijing Dahao Technology Corp., Ltd stall
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- Allen and XU from Zhejiang FZY Machinery Co. Ltd. with Unix team
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- (2nd from R) Paresh Jariwala, Golden Falcon India Pvt. Ltd. with Yuan (3rd from R), Zhuji Maya Electric Appliance Machinery Co., Ltd.
Garmon introduces technology that makes water saving easy
Result of collaboration between three leading companies across the garment finishing market, smart foam simplifies the sustainable practices, helping suppliers of any segment achieve their sustainability goals.
Garmon, the brand for chemical solutions for the denim and fashion industry owned by Kemin Industries, launches smart foam at The Kingpins Show in Amsterdam. Through an innovative patented technology, smart foam has the goal of revolutionizing garment finishing. The system is designed to minimize natural resource consumption, making sustainable garment production easy and accessible.
Innovative
Smart foam is a patented technology, a result of a collaboration of Garmon, Itaclab and Mactec, three leading companies across the garment finishing industry. With smart foam the chemical carrier is not water, but special foam created with a combination of new technologies:
- Garmon’s tested and selected range of chemicals
- easyfoam and easyfoam pro, Garmon’s special foaming agents
- Foam generating equipment recommended by Garmon
The smart foam system can be used to create everything from traditional finishes to unique fashion concepts and styles.
Sustainable
The main benefit of smart foam is the great reduction of water and energy consumption. Compared to traditional washing processes, the application of chemicals through smart foam allows savings of up to 80 percent of water. All the treatments are performed at room temperature, therefore reducing the energy required.
Moreover, when combined with Garmon certified chemicals, smart foam can be used to perform treatments fully compliant with greenofchange® requirements. Overall, smart foam helps suppliers of any segment achieve their sustainability goals, to better serve the fast-moving fashion industry.
Easy
Smart foam has been designed to be the easiest and most affordable system to save water in garment finishing, making the technological investment accessible to any industrial laundry. Compared to nebulization systems, smart foam is up to 3 times faster to load chemicals in the washing machine, and it doesn’t require sealed equipment, allowing technicians to interrupt finishing treatments and check garments with safety and ease. For this reason, any type of washing machine – from the traditional to the advanced – can be utilized with the smart foam equipment and process.
A.T.E.’s focusing on Sustainable Development in India
The average global temperature is on the rise, and according to a report published by a climate watch magazine, Climate.gov, the 10 warmest years on record have all occurred since 1998; 9 of the 10 have occurred since 2005. The report further states that by 2020, the global surface temperature will be more than 0.5°C warmer than the 1986-2005 average.
Countries like India with tropical climates would be hit hard by the increasing temperature. This would lead to an increasing demand for cooling systems. However, conventional cooling systems, mainly the air conditioners, are energy guzzlers and also use the refrigerants that are harmful to the environment. How do we resolve this conundrum?
A.T.E. had the foresight to envisage the urgent need for an alternate eco-friendly technology that would provide cooling and comfort. So, it invested in a nascent technology, about 12 years ago, that has today revolutionised the concept of cooling. The technology, known as IDEC or Indirect Direct Evaporative Cooling, has the well-proven and unique DAMA (dry air most air) as its core, and is based on the principles of evaporative cooling. The DAMA is patented in India, Australia, and the United States. This technology provides comfort cooling using just about 50 percent energy of conventional air conditioners, and replaces the ozone depleting refrigerants used for cooling with nature’s own coolant, i.e., water. In addition, it provides 100 percent fresh air, thus creating a healthy and more productive environment.
A.T.E. is a leader in textile engineering with 80 years of experience and its foray into a totally unrelated territory had surprised many, but A.T.E.’s passion and commitment to environment transcends business and profit to societal wellbeing.
A.T.E.’s cooling business is handled by its business unit HMX which has already supplied more than 60 mn CFM in India and other markets, cooling an area of more than 12 mn sq. ft., encompassing both the industrial and commercial segments and for varying applications. Out of the 60 mn CFM, close to 15 percent of the CFM is supplied to commercial segment. With upto 50 percent power saving compared to air conditioning, this technology offers huge potential to save energy while providing a cool and healthy ambience for the people inside the conditioned space.
It is with the same passion and commitment that A.T.E. also invested in the wastewater business in the year 2008. India, which is home to nearly 18 percent of the world’s population, has only about 4 percent of the world’s water resources. The NITI Aayog’s Composite Water Management Index June 2018 presents a grim water situation in India. As per the report, currently, 600 mn Indians face high to extreme water stress and about two hundred thousand people die every year due to diseases that are linked to inadequate access to safe water. The report goes on to say that the crisis is only going to get worse, and by 2030 the country’s water demand is projected to be twice the available supply, implying severe water scarcity for hundreds of millions of people and an eventual ~6 percent loss in the country’s GDP.
Contributing significantly to India’s water scarcity is the increasing generation of wastewater and its unsafe disposal. Two main sources of wastewater are sewage and industrial waste. It is estimated that around 62,000 mn litres of sewage is generated in India every day, while 13,468 mn litres per day of wastewater is generated by industries in India (FICCI April 2013). A report published by Down to Earth in April 2016 shows that 78 percent of the sewage generated in India is untreated; similar statistics for industrial wastewater are not readily available.
So, why not look at the wastewater as the most secure source of fresh water? With this idea, A.T.E. invested in the business of treatment and recycling of wastewater and was recently joined by HUBER SE, Germany, the world leader in the field, to form A.T.E. HUBER Envirotech Private Limited (AHET).
AHET offers a comprehensive range of solutions for wastewater treatment, recycling, zero liquid discharge and sludge management covering both industrial and municipal sectors. AHET has introduced several novel technologies for industrial wastewater treatment. AAA® technology is a highly successful innovation that treats textile wastewater. AVR® based anaerobic bio-methanation plants have been proven to degrade fat successfully in the dairy industry. AHR handles difficult to treat effluents from pharma and petrochem, whereas SUFRO®, an ultra-high flow submerged UF membranes followed by a reverse osmosis membrane system, provide simple and hassle free recycling of wastewater.
AHET in collaboration with HUBER SE, Germany, also offers innovative and highly efficient equipment for municipal wastewater treatment right from headworks to comprehensive sludge management including faecal sludge treatment. Thus, the endeavour at AHET is to make wastewater the most reliable source of fresh water for industry and mankind.
Another area that A.T.E. invested in that underscores its commitment to the environment is for the development of solar heating solutions. This business is handled by its business unit HMX. With years of R&D and long term in-field testing, A.T.E. has developed an innovative Concentrated Solar Thermal (CST) system that can provide steam (up to 160ºC and 6 bar pressure) and process heat for various industrial and commercial applications.
A.T.E. is also active in the space of Industrial IoT, through its business unit, EcoAxis, which helps businesses improve their bottom lines by unlocking intelligence of things using IoT based advanced analytics. Key environmental benefits of EcoAxis’ IoT solutions are material and energy resource optimisation.
The company’s concern and contributions to the environment also encompasses its own operations, under the theme Aiding The Environment. Two of its newly built facilities are certified green buildings, A.T.E. has installed rooftop solar panels in some of its facilities, and also drives green practices like waste segregation, conservation of power, water, and paper with total employee involvement.
Jeanlogia’s G2 Dynamic guarantees detoxed and sustainable fabric
Jeanologia redefines fabric finishing with G2 Dynamic, the first ozone treatment for continuous fabric, thereby contributing to the consolidation of its objective to attain the dehydration and detoxification of jeans.
G2 Dynamic is the only technology on the market that guarantees a detoxed and sustainable fabric, in addition to reducing water and chemical consumption from 85 percent to 95 percent and energy from 70 percent to 80 percent. For example, if a kilogram of fabric uses between 15 and 20 liters of water, with G2 Dynamic the complete process uses from 0.5 to a maximum of 3 liters per kilo.
This technology has been gaining a lot of traction in the industry, 30 fabric manufacturers have incorporated it into their production process within only three years of its launch. Jean Pierre Inchauspe, the person in charge of G2 Dynamic has pointed out that “the main weavers of the five continents are already using this technology as an indispensable process for the sustainable finishing of their fabrics.”
Jeanologia’s 2025 objective for this technology is to achieve an average saving of more than 8.5 mn cubic meters of water per year. This is the amount necessary for the annual human consumption of more than 3.5 mn people. 80 percent of these machines are being used for the finishing of denim (blue and black) and 20 percent for the finishing of loom state (other colours), the market for “denim fabric” in colour will become more important in the year to come.
With this technology, the company brings to the market a sustainable alternative to several traditional, more polluting and water consuming processes in the textile industry. Furthermore, highlights Inchauspe “[it] improves and boosts subsequent production stages up to the finishing of the garment, making them more efficient and allowing companies to be more competitive, increase productivity and offer a product that is completely sustainable.”
Ozone, a fundamental pillar for a sustainable textile industry
G2 Dynamic is the latest in ecoefficient ozone textile technology, the result of 15 years of innovation in the industry from the fabric to the final garment. After years of applying ozone for garment finishing, Jeanologia has taken the next step using ozone to end the water consumption and chemicals used in traditional fabric finishing processes. The Jeanologia Ozone Center has become one of the fundamental pillars in the new era for denim as an essential element in a 100 percent sustainable textile industry.
