SPACE

Volume 03, Issue 04, 46 Pages

April 2025

 www.texspacetoday.com

ROI of Robotic Sewing:

Where do automation
investments truly pay off?

Sustainability Updates More at...5 Precision Updates More at...16 Automation Updates More at...22

Circularity Updates More at...26 Energry Updates More at...38

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 Volume 03, Issue 04, 46 Pages
April 2025

Editor in Chief
Tareq Amin

Managing Editors
Eousup Abu Abdullah
SK Saha
Rahbar Hossain
M A Mohiemen Tanim

Executive Editors
Sayed Abdullah
Arif Uz Zaman

Special Editors
Muddassir Rashid
Setara Begum

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Amzad Hossain

Design
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Hasan Miah

Cinematographer
Ashraful Alam

A Textile Today Innovation Hub publication.

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Volume 03, Issue 04 (April 2025)
 Volume 03, Issue 04, 46 Pages
April 2025

Content April 2025

CSRD & CSDDD officially ROI of Robotic Sewing: Where do

5-7 delayed by European
22-25 automation investments truly pay off?
Parliament

Refiberd wins CFDA x eBay

India’s ‘Sporttech Pavilion’ to highlight 26-27
07 sustainable sportswear tech
circular fashion fund

British fashion manufacturing Simplifyber secures series A funding

08 eyes resurgence amid global
28 for fully biodegradable garments
realignments
Matoha secures £1.5 million to
EIM releases first global report on
32 enhance AI-based material scanning
9-10 denim industry’s environmental in textile recycling
impact
Syre launches gigascale textile
Run & Relax introduces SS25 33 recycling plant in Vietnam
12 activewear using Q-NOVA® by Fulgar

EU mandates separate textile

Cambodia gains market 34 waste collection by 2025
13 share in swiss apparel sector

Kering launches industry-first

GALLS® acquires 35
14 HerBlueWear Uniforms™
water strategy

Bangladesh’s textile waste crisis

36 spurs recycling push
Functional Fabric Fair 2025 (USA)
15 showcases sustainable innovation

Solar cell fabrics open new

Montana technologies unveils 37 chapter in wearable energy
16 ultra-efficient cooling system

China scales up Compressed-Air

Smart Grids bring precision 38-40 Energy Storage (CAES)
17 power to manufacturing

Sodium-Ion batteries offer hope

Trützschler, O.R.V. & Texnology achieve 41
18 breakthrough in precision filtration
for sustainable power storage

True cost of steam: An energy

19-20 Innovative automated stretch 42-44 audit across wet processing units
elastic waistband sewing machine
in south asia

Jay Apparel Group expands operations Low carbon thermal energy

21 in central america to navigate tariff crisis 45 roadmap released
 S U S T A I N A B I L I T Y

Photo: EU Parliament ©️DW

CSRD & CSDDD

officially delayed by
European Parliament
Daniel Brown

European Parliament has officially stringent requirements.

delayed the implementation of two
The decision, part of the broader
landmark sustainability regulations,
Omnibus Simplification Package aimed
the Corporate Sustainability Reporting
at reducing administrative burdens and
Directive (CSRD) and the Corporate
enhancing EU competitiveness, pushes
Sustainability Due Diligence Directive
back the CSRD reporting timeline for
(CSDDD), following a decisive vote
certain companies by two years and
on April 3, 2025. With 531 votes in
delays the CSDDD’s first phase by one
favor, 69 against, and 17 abstentions,
year. Large companies with more than
Members of the European Parliament
250 employees, originally set to begin
(MEPs) overwhelmingly supported the
CSRD reporting in 2026 or 2027, will
European Commission’s “stop-the-
now start in 2028 for the fiscal year
clock” proposal, granting companies
2027. Listed small and medium-sized
additional time to comply with the

April 2025 Sustainability - Precision - Automation - Circularity - Energy 5

enterprises (SMEs) have until 2029 the postponement as a way to ease
to comply. Meanwhile, the largest compliance pressures, it has sparked
companies under the CSDDD—those debate among environmental
with over 5,000 employees and €1.5 advocates and some lawmakers.
billion in turnover—will also see their MEP Tilly Metz criticized the lack
compliance timeline deferred to 2028, of an impact assessment or public
with member states granted until July consultation prior to the decision,
2027 to transpose the directives into warning that “rolling back sustainability
national law. laws under the guise of cutting red tape
will not solve the structural problems
The European Commission first
of the European economy.” Others,
proposed the delay in February 2025,
however, see the delay as a pragmatic
citing the need to simplify the bloc’s
step, giving businesses clarity and
corporate sustainability frameworks
breathing room to adapt to the new
amid concerns from businesses about
rules.
the regulatory burden. The CSRD
requires companies to report on their The Omnibus Package also includes
environmental and social impacts, while proposed changes to the scope and
the CSDDD mandates due diligence content of both directives. For the
to identify and address human rights CSRD, the threshold for compliance
and environmental risks in supply may be raised to companies with over
chains. Critics of the original timelines 1,000 employees and €50 million in
argued that the requirements were revenue, potentially excluding up to
overly complex, particularly for smaller 80% of previously covered companies.
companies, and could hinder economic For the CSDDD, companies will now
competitiveness in a challenging global only be required to conduct full due
climate. The delay was formalized diligence beyond direct partners if
after the European Council endorsed they have credible evidence of adverse
the draft text on March 26, with the impacts deeper in the supply chain—a
Parliament’s approval on April 3 marking significant reduction from the original
the final legislative step. The European requirement for systematic in-depth
Financial Reporting Advisory Group assessments.
(EFRAG) has been tasked with revising
Across the Atlantic, the delay has
the European Sustainability Reporting
drawn attention from U.S. policymakers.
Standards (ESRS) under the CSRD, with
House Financial Services Chair French
a seven-month deadline to reduce the
Hill (R-Ark.) described the CSDDD as a
number of required data points and
“non-tariff barrier” for U.S. companies,
streamline reporting processes.
while Senator Bill Hagerty (R-Tenn.)
While the move has been welcomed recently introduced a bill to bar U.S.
by industry groups, including the firms deemed “integral to national
insurance sector, which endorsed interests” from complying with

6 Sustainability - Precision - Automation - Circularity - Energy April 2025

foreign sustainability due diligence While the delay offers companies a
laws, signaling potential transatlantic reprieve, experts urge businesses to
tensions over the EU’s green agenda. continue preparing, as sustainability
reporting and due diligence will
As the EU shifts focus to broader
eventually become mandatory. For
reforms of its sustainability frameworks,
now, the decision marks a significant
the Legal Affairs Committee of the
recalibration of the EU’s ambitious
European Parliament will now begin
Green Deal, balancing environmental
work on the substantive changes
goals with economic realities in an
proposed in the Omnibus Package.
increasingly complex global landscape.

India’s ‘Sporttech Pavilion’

to highlight sustainable
sportswear tech
Matthew Davis

Photo: Raj Manek (Right), Executive Director & Board Member, Messe Frankfurt Asia
Holdings Ltd and Kishan Daga (Centre), Anchor Founder, Concepts N Strategies

Techtextil India 2025 will introduce the integration. Products on display will
“Sporttech Pavilion,” a curated showcase include antimicrobial knits, low-impact
of India’s emerging sustainable sports dyeing systems, and biosensor-enabled
and performance fabric suppliers. athletic gear.

The initiative, backed by Messe India’s competitive cost structure and

Frankfurt, aims to position India as a manufacturing base could make it a
destination for innovation in functional serious contender in the high-growth
fabrics, moisture control, and wearable global sportwear segment.

April 2025 Sustainability - Precision - Automation - Circularity - Energy 7

S U S T A I N A B I L I T Y

British fashion manufacturing

eyes resurgence amid global
realignments
Matthew Davis

As global fashion supply

chains continue to adapt
to geopolitical tensions
and environmental
imperatives, British
fashion manufacturing
is experiencing an
unexpected resurgence.
A combination of rising
import tariffs, supply Photo: UK's David Nieper Ltd employs more than 300 staff
chain fragility, and
increased sustainability Government initiatives and a reduction in
legislation is making are playing a role too. emissions linked to global
domestic production “Made Smarter” and transport. With upcoming
attractive once again. the “UK Manufacturing EU-style regulations
Renaissance” grants are expected to mandate
A recent report by the
helping SMEs digitize environmental disclosures,
UK Fashion and Textile
their operations and local sourcing may soon
Association (UKFT) reveals
improve energy efficiency. offer not just a cultural
that inquiries for local
At the same time, public edge, but a compliance
sourcing have risen by 35%
sentiment toward ethical advantage.
since late 2024. Luxury
consumption is rising—
houses such as Burberry If momentum holds,
especially among younger
and emerging brands Britain could see the
consumers and export
like Phoebe English emergence of regional
clients demanding full
are expanding British micro-factories and
traceability.
workshops, with a focus cooperative production
on low-waste pattern UK-based production models—redefining what
cutting, regenerative also allows for tighter “Made in the UK” means
textiles, and artisan-level feedback loops between for the 21st-century
finishing. designers and makers, fashion economy.
faster turnaround times,

8 Sustainability - Precision - Automation - Circularity - Energy April 2025

 S U S T A I N A B I L I T Y

Photo: EU Parliament ©️DW

EIM releases first global

report on denim industry’s
environmental impact
Luke Wilson

In a groundbreaking move toward The report reveals encouraging

greater transparency and sustainability, progress, highlighting that 63% of
Environmental Impact Measuring assessed denim finishing processes
(EIM), the global platform created by have already been classified as having
technology innovator Jeanologia, has minimal environmental impact. This
released its first comprehensive report indicates a positive trend toward
titled “The Innovations and Challenges responsible production practices within
in Denim Finishing: 2024 Report.” the global denim industry.
This milestone document provides a
However, the report also underscores
detailed overview of the environmental
critical areas of concern. Notably,
footprint of the denim finishing sector
24% of the processes still involve
based on data collected from over
hazardous chemicals, such as potassium
115,000 operations worldwide.

April 2025 Sustainability - Precision - Automation - Circularity - Energy 9

permanganate and pumice stones. chemicals and increased automation
These substances are known to be and digitalisation of production
harmful not only to the environment processes. These innovations not only
but also to workers’ health. The report help reduce chemical consumption but
stresses the urgent need to transition also enhance worker safety and overall
toward safer, more sustainable process efficiency.
alternatives. Water consumption,
Since its inception in 2009, and global
a long-standing issue in denim
implementation beginning in 2011, the
production, remains a key challenge.
EIM platform has grown into a trusted
On average, 30 litres of water are
benchmark for sustainability within the
used per garment in denim finishing,
denim industry. Major global retailers
exceeding the recommended 22.5
and brands including H&M, Levi’s,
litres. To combat this, the report
M&S, AEO, Primark, Mango, Guess,
suggests implementing advanced
Tommy Hilfiger, and C&A now rely
technologies such as ozone, e-flow, and
on EIM to measure and manage their
smart foam systems, which have proven
environmental performance.
to significantly reduce water usage.
Additionally, adopting textiles that As the industry continues to face
require less intensive treatments and mounting pressure to adopt sustainable
optimising rinse procedures can further practices, EIM’s data-driven insights
improve water efficiency. provide a much-needed roadmap for
meaningful change—paving the way for
Another major recommendation
a more responsible denim future.
is the adoption of ZDHC-certified

10 Sustainability - Precision - Automation - Circularity - Energy April 2025

 Delegation to China
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Led by Textile Today Business Hub

11-13 June 2025

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and Exhibition Center
Futian District, China

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April 2025 Sustainability - Precision - Automation - Circularity - Energy 11

 S U S T A I N A B I L I T Y

Run & Relax introduces SS25

activewear using Q-NOVA®
by Fulgar
Luke Wilson

Scandinavian activewear brand Run & and light training audiences. The SS25
Relax has unveiled its Spring/Summer line includes leggings, crop tops, and
2025 collection featuring Q-NOVA® by breathable jackets, with pastel tones
Fulgar—a nylon yarn made from 99% inspired by Nordic nature.
recycled raw materials. The launch
This move aligns with growing demand
represents the brand’s deepening
for eco-conscious activewear in Europe
commitment to sustainability without
and Asia, particularly among millennial
compromising on performance.
and Gen Z consumers. Fulgar, the
Run & Relax’s new line emphasizes Italian yarn producer behind Q-NOVA®,
minimalist Scandinavian design, has also reported increased uptake
enhanced by moisture-wicking, across fashion and sportswear brands,
lightweight, and stretchable properties highlighting the material’s scalability.
intrinsic to Q-NOVA®. The material
Retail analysts predict that
is certified by the Global Recycled
collaborations like these will become
Standard (GRS) and produced via
the norm as consumers demand
a mechanical process with low
transparency, and brands compete to
environmental impact.
marry form, function, and footprint. The
Founded in Norway, the brand is collection is already available on the
known for merging mindfulness and Run & Relax website and select retail
movement, catering to yoga, Pilates, partners across Europe.

12 Sustainability - Precision - Automation - Circularity - Energy April 2025

T R A D E

Cambodia gains market

share in swiss apparel sector
Benjamin Harris

Cambodia has made notable strides standards required by European buyers.

in expanding its footprint in global
Trade analysts suggest that Cambodia’s
apparel markets, particularly in
preferential trade arrangements under
Switzerland. According to recent trade
the EU’s Everything But Arms (EBA)
data, Cambodia’s apparel exports
initiative have played a critical role.
accounted for 3.14% of Switzerland’s
While Switzerland is not part of the EU,
total apparel imports in early 2025,
it has a number of bilateral agreements
marking a significant increase from
that align with EBA principles, making
previous years.
Cambodian garments attractive due to
This growth reflects Cambodia’s lower duties.
improved manufacturing infrastructure
Western brands are diversifying
and competitiveness in cost-effective
their sourcing away from China
garment production. The country’s
due to rising costs and geopolitical
factories, primarily clustered around
tensions. This has opened doors for
Phnom Penh and Sihanoukville, are
Cambodian manufacturers, who offer
increasingly equipped with modern
a blend of price competitiveness and
machinery and quality control systems.
improving compliance with labor and
These upgrades have enabled
environmental standards.
Cambodian exporters to meet the high

April 2025 Sustainability - Precision - Automation - Circularity - Energy 13

 S U S T A I N A B I L I T Y

GALLS® acquires
HerBlueWear Uniforms™
William Moore

GALLS®, a leading supplier of public uniforms.

safety and tactical gear, has officially
With this acquisition, GALLS® plans to
acquired HerBlueWear Uniforms™,
integrate HerBlueWear’s design principles
a brand known for its tailored
into its broader product line, expanding
apparel solutions for women in law
its reach across police departments, fire
enforcement. The acquisition marks a
services, and federal agencies. The move
significant step toward inclusivity and
also reflects growing industry attention
functional design in the uniform market.
to diversity, equity, and inclusion—not
HerBlueWear, founded by a former law just in staffing but also in product design
enforcement officer, was created to and procurement practices. Executives
fill a longstanding gap in the market: at GALLS® noted that this acquisition
professional, durable, and well-fitting aligns with their mission to “serve those
uniforms for female officers. The brand who serve,” and addresses evolving
has gained loyalty for prioritizing needs in uniform technology, gender
comfort, performance, and aesthetics responsiveness, and workplace comfort.
tailored to women’s body types—an Product rollouts combining both brands
often overlooked area in standard-issue are expected by Q3 2025.

14 Sustainability - Precision - Automation - Circularity - Energy April 2025

 E X H I B I T I O N

Functional Fabric Fair

2025 (USA) showcases
sustainable innovation
Jack Thompson

Portland’s 2025 Functional Fabric Fair New entrants showcased AI-integrated

brought together over 300 exhibitors textiles, antimicrobial knits made
and thousands of visitors from April from seaweed fibers, and waterproof
14–16, reinforcing the industry’s membranes with zero PFAS content.
growing commitment to sustainable Attendees also explored tools for
performance materials. lifecycle assessments and blockchain-
backed certification audits. The event
Highlights included innovation zones
proved that performance doesn’t need
focused on biodegradable synthetics,
to come at the planet’s expense—
bio-based finishes, and traceable
and that suppliers are racing to meet
functional fabrics. A dedicated Day 0
stringent global demands for greener,
Sustainability Workshop offered tools
cleaner, traceable materials.
to assess environmental impact during
fabric selection and sourcing.

April 2025 Sustainability - Precision - Automation - Circularity - Energy 15

 P R E C I S I O N

Montana technologies
unveils ultra-efficient
cooling system
Harry White

Montana Technologies has introduced electricity bills dropped by nearly half,

a breakthrough in air conditioning and the ambient environment became
technology with its AtmosZero™ more consistent—reducing fabric defects
dehumidification system—an innovation and machine wear.
that could slash cooling energy
Beyond textiles, the system is gaining
consumption in textile factories by up to
attention from semiconductor and
90%.
pharmaceutical industries, where
Unlike conventional HVAC systems that moisture control is equally critical. The
cool and dehumidify air simultaneously, cooling units are modular, easy to retrofit,
AtmosZero separates these processes. and can run on low-carbon refrigerants—
It uses a patented desiccant-based making them a fit for LEED and EDGE-
system to remove humidity before the air certified green buildings.
reaches the cooling coil. This significantly
Montana Technologies is scaling its
reduces the workload of the compressor,
production and exploring strategic
which is the most energy-intensive
partnerships with apparel brands that
component.
have committed to carbon neutrality.
In textile manufacturing, especially Analysts view this as a key development
in tropical regions like South Asia, in meeting Science Based Targets (SBTi)
maintaining low humidity is essential for for energy-intensive industries.
yarn strength, dye precision, and machine
As climate change accelerates, cooling
efficiency. Traditional cooling methods,
demand is projected to triple by 2050.
however, are highly power-intensive and
Technologies like AtmosZero offer a
often unreliable during grid fluctuations.
path to meet this demand responsibly,
Early pilot installations of AtmosZero in especially for sectors like textiles where
Vietnamese spinning and dyeing units heat and humidity are unavoidable
have shown dramatic results. Monthly variables in quality and productivity.

16 Sustainability - Precision - Automation - Circularity - Energy April 2025

 P R E C I S I O N

Smart Grids bring

precision power to
manufacturing
Daniel Brown

As renewable energy integration

becomes a core objective for industrial
sustainability, smart grid technology
is stepping up as a precision tool for
modern manufacturing—including the
textile and apparel sector. Smart grids
use digital communication, AI, and
IoT sensors to monitor, distribute, and
optimize electricity usage in real time.
frameworks. Many smart grid systems
Unlike traditional power grids, which
include dashboards and APIs that
operate on fixed schedules and
track scope 2 emissions in real time—
centralized control, smart grids allow
useful for meeting international buyer
dynamic load balancing. In industrial
requirements for transparent energy
parks or manufacturing zones, this
usage.
means diverting power to energy-
intensive operations when demand One leading example is the “Smart
is low and pulling from renewable or Textile Cluster” initiative in Portugal,
stored energy during peak hours. where mills are connected through a
shared grid powered by hydro and
In Europe and parts of Asia, smart grid
solar energy. The system allocates
pilots have demonstrated energy
power based on real-time efficiency
savings of 10–15% in textile dyeing
scores, creating a benchmark model for
and finishing facilities. Factories can
scalable, data-driven sustainability.
forecast load demands, prioritize low-
emission energy sources, and receive Smart grids are expected to become an
automated alerts for maintenance and industry norm by 2030, especially in light
anomalies. These grids also support of increasing climate-related disruptions
“demand response” incentives, where and volatile energy pricing. For textile
users are rewarded for reducing usage manufacturers, early adoption provides
during critical hours. The digitization a competitive edge—not just in cost
of power infrastructure also ties into savings, but in proving environmental
carbon reporting and compliance accountability to global brands.

April 2025 Sustainability - Precision - Automation - Circularity - Energy 17

 P R E C I S I O N

Trützschler, O.R.V. & Texnology

achieve breakthrough in
precision filtration
Matthew Davis

In a remarkable
demonstration of
collaborative engineering
and technical innovation,
O.R.V. MANUFACTURING
S.P.A., Texnology s.r.l., and
Trützschler Nonwovens
have successfully
completed a milestone
R&D trial at Trützschler’s
Technical Center in Photo: The Team Behind the Development
of Precision Filtration Technology
Egelsbach, Germany.
This high-stakes two- » 11 product variations Engineering at Its Best
day trial marked a from 25 gsm to 850 gsm
Trützschler Nonwovens’
significant step toward
To meet these engineering team worked
the development of
challenges, the team in close coordination with
next-generation filtration
leveraged Trützschler’s O.R.V.’s production and
products designed to
T-Suprema needle R&D units, ensuring real-
meet complex industrial
punching line, a solution time problem-solving and
requirements.
that demonstrated solution implementation.
Meeting Complexity exceptional versatility According to the team,
with Precision and precision throughout the trial not only validated
the process. The success the capabilities of the
The trial tackled an of the trial underlined T-Suprema line but also
ambitious scope, the T-Suprema’s ability laid the groundwork for
involving: to adapt to complex one of Europe’s largest
» 11 different fibers product parameters and filtration production
ranging from 1 to 40 Dtex customize performance to lines – a significant
specific client demands. leap forward for the
» 7 distinct fiber blends
nonwovens sector.

18 Sustainability - Precision - Automation - Circularity - Energy April 2025

 P R E C I S I O N

Photo: Elastic band pulling apart test to measure the elongation

Innovative automated
stretch elastic waistband
sewing machine
Luke Wilson

A new research paper published fabric specifications, eliminating

on arXiv has unveiled an innovative inconsistencies in seam strength and
automated sewing machine designed stitch uniformity. With its intelligent
specifically for attaching stretch feedback loop, the machine adjusts
elastic waistbands, commonly used needle speed and feeder tension in
in activewear and intimate apparel. real time, ensuring precision at high
The breakthrough technology production speeds. Researchers claim
integrates sensors, motor controls, and that the prototype can reduce labor
synchronized feeders to handle variable input by 70%, while increasing output
elasticity and fabric tension, a task consistency and reducing defect rates.
traditionally dependent on skilled labor. The adoption of such machines could
transform mid-sized factories that
The system features a sensor-
struggle to maintain product quality
based waistband expansion unit
during scale-up.
that automatically adjusts to

April 2025 Sustainability - Precision - Automation - Circularity - Energy 19

The research emphasizes that from OEMs and automation providers.
integrating such machines into lean
The innovation represents a significant
production systems can also improve
step forward in precision automation
ergonomics and reduce repetitive
for apparel manufacturing, particularly
strain injuries among operators.
as brands seek higher quality standards,
Pilot testing in select Bangladeshi
labor cost control, and just-in-time
and Vietnamese factories has shown
production capabilities.
promising results, sparking interest

Photo: Elasticity control schematic diagram

20 Sustainability - Precision - Automation - Circularity - Energy April 2025

 T R A D E & B U S I N E S S

Jay Apparel Group expands

operations in central america
to navigate tariff crisis
Oliver Taylor

Jay Apparel Group, a U.S.-based

apparel company headquartered in
New York, has announced a significant
expansion into Central America. This
strategic move is aimed at countering
the impact of rising tariffs and supply
chain disruptions by relocating and
diversifying its manufacturing operations
closer to the North American market. Central America Free Trade Agreement
In response to shifting trade dynamics and (CAFTA-DR), enabling duty-free access
the global tariff crisis, Jay Apparel Group to the U.S. market and encouraging
will establish new production facilities in investment in the region.
Honduras and other key Central American The expansion is projected to create
locations. The decision comes amid hundreds of new jobs, support local
growing pressure on apparel manufacturers economies, and reinforce Jay Apparel
to reduce lead times, manage costs, and Group’s commitment to responsible
maintain agility in sourcing. sourcing and innovation. By reducing
“Central America offers an exceptional dependency on Asian manufacturing
opportunity for nearshoring due to its hubs, the company seeks to build a more
proximity, favorable trade agreements, resilient and responsive supply chain.
and growing textile infrastructure,” said Industry analysts view this move as
Jay R. Kapadia, President of Jay Apparel part of a broader trend among apparel
Group. “This expansion will allow us to brands reconsidering global sourcing
enhance flexibility, mitigate tariff exposure, strategies in light of economic volatility,
and continue delivering value to our retail transportation bottlenecks, and
partners.” The company’s operations in geopolitical uncertainties. Nearshoring
Central America will focus primarily on to Central America is increasingly seen
producing men’s woven sport shirts and as a viable long-term strategy for North
other core product categories. The new American apparel companies aiming to
facilities will take advantage of benefits improve speed-to-market and reduce
provided under the Dominican Republic– exposure to external shocks.

April 2025 Sustainability - Precision - Automation - Circularity - Energy 21

 A U T O M A T I O N

Photo: ROI of Robotic Sewing: Where do automation investments truly pay off?

ROI of Robotic Sewing:

Where do automation
investments truly pay off?
M A Mohiemen Tanim

As the global apparel industry grapples that can stitch garments with minimal
with rising labor costs, shrinking lead human intervention while maintaining
times, and increasing pressure for consistency, speed, and quality. In theory,
compliance and quality consistency, automation reduces:
robotic sewing has emerged as a
» Labor dependency in a tight-skilled
futuristic yet pragmatic solution. From
labor market
sew-bots to semi-automated modules,
the conversation has shifted from “Will » Human error, especially in quality-
this work?” to “Where does it work best?” sensitive segments

» Lead times, aligning with fast fashion

The Promise of Robotic Sewing and just-in-time production
At the heart of robotic sewing lies the However, in practice, the implementation
vision of automated precision: machines of robotic sewing is neither universal

22 Sustainability - Precision - Automation - Circularity - Energy April 2025

nor equally beneficial across all product Why It Works:
types or production contexts. ROI
Minimal panel variation and seam
varies significantly based on garment
complexity
complexity, production volume, and
integration capabilities. Easily programmable repetitive tasks
(e.g., sleeve attach, hem folding)
Breaking Down the Investment Large production batches amortize
CapEx faster
Initial Capital Expenditure
(CapEx): ROI Snapshot:
» A fully automated robotic sewing unit A robotic T-shirt sewing line operating
(e.g., from SoftWear Automation or 24/7 can reduce labor costs by up to 60%,
Sewbotics) can cost between $100,000 and recover the investment within 18–24
to $350,000. months in high-wage countries like the
» Semi-automated modular workstations, U.S. or Germany.
like programmable sewing arms or
edge-alignment robots, range from Case Example:
$15,000 to $60,000 per station. SoftWear Automation’s T-shirt sewbot
platform, tested in Atlanta, reported
Integration and Training: production speeds of 1 shirt every 22
» Additional costs include integration seconds, with quality metrics matching or
with ERP/MES systems, technician exceeding human benchmarks.
training, factory floor modification, and
downtime during the learning curve. Factories in High-Wage or
Compliance-Intensive Zones
Operational Costs: In countries with high labor costs or tight
» Electricity consumption, preventive compliance regulations, automation
maintenance, and consumables like improves not only cost efficiency but also
sensors or robotic fingers need to be audit readiness.
factored into Total Cost of Ownership
(TCO). Strategic Gains:
» Reduced worker fatigue and injury risks
Where ROI Makes Sense (especially in repetitive strain tasks)
T-Shirts and Basic Knits (High Volume, Low
» Enhanced traceability and quality
Complexity)
tracking
The sweet spot for robotic sewing lies in
» More stable operations in volatile labor
high-volume, low-skill garments — think
markets
T-shirts, briefs, or socks.

April 2025 Sustainability - Precision - Automation - Circularity - Energy 23

Seam-Specific Automation Insight:
(Instead of Full Garment) A blazer may involve 80+ operations,
Full-garment automation may be elusive many requiring nuanced handling.
for now, but partial robotic integration Attempting to automate these fully
(seam or function-specific) offers often leads to low utilization of expensive
measurable ROI. robotic units, diminishing ROI.

High-ROI Applications: Low-Wage Manufacturing Hubs

» Automated bartack machines for belt In regions like Bangladesh, Ethiopia,
loops or pockets or Myanmar where labor costs remain
low, the labor substitution advantage
» Elastic waist attach modules with
is minimal. ROI may take 5–7 years,
tension sensors
often outpaced by labor turnover and
» Collar setting or cuff pressing modules operational reconfiguration needs.
with robotic feeders
However, these regions could benefit
Financial Insight: from automation in finishing and quality
inspection, which adds value without
Adding a $20,000 robotic waistband displacing jobs drastically.
attachment unit can reduce manpower
by 2 operators and improve cycle time by Strategic Metrics to Evaluate ROI
25%, resulting in ROI in 12–18 months for
To go beyond pure financial metrics,
mid-scale factories.
ROI in robotic sewing should also be
Where ROI Falls Short evaluated using:

High-Complexity Garments (e.g., Metric Description

Jackets, Dresses, Denim Tops)
Cost per Total operating cost
Precision handling of varied fabrics, Garment divided by units
variable seam directions, or intricate (CPG) produced
styling elements remains a challenge for OEE (Overall Measures machine
full automation. Garments that require: Equipment availability, performance,
Effectiveness) and quality output
» Drape control
Indicates machine
» Manual folding or pleating Uptime % reliability and
» Multi-layer sewing with shifting fabric maintenance efficiency
densities Defect Rate Tracks improvement in
Reduction quality consistency
still rely heavily on human dexterity.
Time-to- Measures acceleration in
Market delivery lead times

24 Sustainability - Precision - Automation - Circularity - Energy April 2025

The Hybrid Model: Human + » Sustainability-linked sourcing premiums
Machine Collaboration (automation reduces waste, rework, and
energy)
The future of sewing isn’t about replacing
workers, but augmenting them. A hybrid Governments in Vietnam, China, and
workstation where operators handle Indonesia are also offering automation
fabric alignment and machines execute subsidies or tax breaks to accelerate
precision stitching can deliver: smart factory adoption.

» Faster learning curves

Conclusion: Robotic ROI Is About
» Flexible batch runs Fit, Not Fantasy
» Lower CapEx with faster ROI Robotic sewing delivers strong ROI
Companies like Juki, Durkopp Adler, when the product type, volume, and
and Pegasus are leading this hybrid shift labor context align. It’s not about full
with IoT-embedded smart machines, automation of fashion production
touchless foot control, and AI-assisted today, but about precision targeting of
stitch programs. repetitive, high-waste, or high-risk tasks.

In the long term, factories that build

Policy and Brand Push: ROI Beyond modular, scalable automation ecosystems
the Factory — combining robotics, AI, and operator
Several brands and buyers are expertise — will lead the SPACE
incentivizing automation by offering: (Sustainability, Precision, Automation,
Circularity, Energy) transformation of
» Volume commitments to justify CapEx
textile and apparel manufacturing.
» Shared investment models

April 2025 Sustainability - Precision - Automation - Circularity - Energy 25

 C I R C U L A R I T Y

Photo: ©️Photo: Brad Geyer | Vogue Business

Refiberd wins CFDA x eBay

circular fashion fund
Benjamin Harris

In a notable development for circular the mislabeling of fabrics and the

fashion and textile innovation, Refiberd, complexity of fiber blends. By accurately
a U.S.-based startup, has been awarded identifying materials, Refiberd’s system
the top prize in the CFDA x eBay Circular facilitates effective textile-to-textile
Fashion Fund competition, securing a recycling, which is essential for scaling
$300,000 grant from eBay Ventures. circular economy models in the apparel
The award recognizes startups that are sector. Co-founders Sarika Bajaj, Annette
pushing the boundaries of circularity and Chang, and Maia Zhang emphasized that
sustainability in the fashion industry. this grant will accelerate their R&D efforts
and enable broader partnerships with
Refiberd has garnered industry attention
recyclers and fashion brands. Their long-
for its cutting-edge use of hyperspectral
term goal is to eliminate the need for
imaging and artificial intelligence to
virgin fiber production by making high-
sort and identify textile fibers. This
quality recycling scalable and efficient.
technology addresses one of the most
The CFDA x eBay Circular Fashion Fund is
persistent challenges in textile recycling:

January 2025 Sustainability - Precision - Automation - Circularity - Energy 26

 Photo: ©️Photo: Brad Geyer | Vogue Business

part of a broader industry push toward extending product life cycles. The
sustainability. Launched in 2023, the marketplace platform has long been a
initiative seeks to foster innovation that hub for resale, and this partnership with
reduces waste and increases circularity CFDA marks its deepening commitment
across the fashion value chain. This year’s to environmental stewardship in fashion.
finalists included emerging players
This win not only highlights the potential
working on resale technology, rental
of technology to drive sustainable
infrastructure, and biodegradable
innovation but also positions Refiberd
textiles, but Refiberd stood out due to its
as a critical player in the future of fashion
highly technical approach and real-world
recycling infrastructure. With support
impact.
from eBay and the CFDA, the startup is
eBay’s involvement in the circular fashion well poised to contribute significantly to
space aligns with its strategic goal of reducing fashion’s global waste footprint.

27 Sustainability - Precision - Automation - Circularity - Energy January 2025

 C I R C U L A R I T Y

Simplifyber
secures series
A funding
for fully
biodegradable Photo: THE FOOTWEAR OF THE FUTURE:
Simplifyber's soft, fabric-like shoe uppers are

garments
created from a cellulose-based liquid, and are
fully biodegradable and recyclable.

William Moore

Simplifyber, a New York-based material material waste by up to 60% and

innovation startup, has raised Series A eliminating microplastic shedding. The
funding to advance its groundbreaking materials are compostable at end-of-life
approach to sustainable garment and consume significantly less water than
production. The company develops cotton or synthetic blends.
fully biodegradable, molded garments
The startup is currently piloting apparel
using liquid cellulose derived from wood
lines with select fashion and athletic
pulp—bypassing traditional cut-and-sew
brands and expects to roll out co-
processes entirely.
branded products by early 2026. Industry
The funding round, led by At One observers have noted Simplifyber’s
Ventures with participation from potential to disrupt not only fashion but
H&M Group Ventures and Techstars, also packaging and home textiles.
underscores growing investor confidence
CEO Maria McManus stated, “Our
in next-gen textile solutions. Simplifyber
mission is to transform manufacturing
plans to use the capital to scale its
from a waste-heavy, toxic process to a
proprietary fiber-molding technology,
regenerative, nature-based system.” With
expand its production capacity, and enter
consumer demand for biodegradable
new market segments.
and ethically sourced apparel growing,
Unlike conventional garments, Simplifyber’s innovation could mark a
Simplifyber’s products are formed in turning point in how fashion is made.
three-dimensional molds, reducing

28 Sustainability - Precision - Automation - Circularity - Energy April 2025

 C I R C U L A R I T Y

Craftevo Japan: Leading the

Charge in Sustainable Textiles
Sas Enterprise

In the dynamic world of sustainable for composting, consumers can actively

fashion, Craftevo Japan, a brand under participate in reducing landfill waste
V&A Japan Corporation, is making and lowering carbon emissions².
waves with its innovative and eco-
Product Details
friendly textile solutions. Renowned
for their dedication to environmental 1. ReTE Polyester: Engineered to break
sustainability, Craftevo’s products are down through hydrolysis when exposed
designed to minimize waste and carbon to moisture, heat, and microorganisms
emissions, setting a new benchmark in in compost². This process significantly
the textile industry. reduces the environmental footprint
compared to traditional polyester,
Innovative Products
cutting CO2 emissions by 40% during
Craftevo’s flagship product line, disposal². The ReTE polyester maintains
**ReTE**, features a revolutionary its durability during regular use,
type of polyester that decomposes ensuring that it meets the functional
into water and carbon dioxide under needs of consumers while being eco-
specific composting conditions². This friendly at the end of its life.
groundbreaking material is not only
2. Collection and Composting: Craftevo
durable during regular use but also
encourages customers to return used
environmentally friendly at the end of
products, which are then processed in
its lifecycle. By returning used products
composting facilities². This initiative

April 2025 Sustainability - Precision - Automation - Circularity - Energy 29

promotes a circular economy, where their commitment to leading the
products are sustainably returned to charge in sustainable fashion and
the earth. The company has set up textile innovation. These platforms
collection boxes in stores and provides have allowed Craftevo to connect with
return options for customers, making it industry leaders, potential partners, and
easy for them to participate in this eco- consumers who are passionate about
friendly initiative². sustainability.

3. Product Identification Tags: Each Future Prospects

product made with ReTE polyester
As the demand for sustainable
comes with a unique identification tag,
products continues to grow, Craftevo
allowing for easy tracking and return
Japan is well-positioned to expand
for composting². This system ensures
its market reach. Their focus on
that every product can be properly
creating environmentally responsible
processed at the end of its lifecycle,
textiles aligns with global efforts to
further reducing environmental impact.
combat climate change and promote
Environmental Impact sustainability in the fashion industry.
The company plans to continue
The ReTE polyester is designed to
innovating and expanding its product
break down through a process called
line to meet the evolving needs of eco-
hydrolysis, where moisture, heat, and
conscious consumers.
microorganisms in compost cause the
material to decompose into water For more information about Craftevo
and carbon dioxide². This process Japan and their products, visit their
significantly reduces the environmental [official website](https://www.craftevo.
footprint compared to traditional com/)¹.
polyester, cutting CO2 emissions by
Craftevo Japan is setting a remarkable
40% during disposal². By encouraging
example in the textile industry
customers to return used products
by combining innovation with
for composting, Craftevo is actively
sustainability. Their products not
promoting a circular economy and
only meet the functional needs of
reducing landfill waste².
consumers but also contribute to a
Market Presence healthier planet. In Bangladesh, RH
CORPORATION is offering the products
Craftevo has showcased its innovative
of Craftevo Japan to revolutionize
textiles at various international events,
the textile industry of Bangladesh
including the Sustainable Fashion
under the umbrella of RH GREEN, for a
Expo and Premier Vision Paris². Their
greener and more sustainable future.
presence at these events highlights

30 Sustainability - Precision - Automation - Circularity - Energy April 2025

 C I R C U L A R I T Y

Photo: Matoha team

Matoha secures £1.5 million

to enhance AI-based material
scanning in textile recycling
Jack Thompson

accurately sorting complex textile

Our technology enables blends for recycling.
high-speed, accurate
With textile waste growing rapidly and
fiber detection at the
point of sorting. This less than 1% of discarded garments
is a game changer for being recycled into new clothes,
textile circularity,” said Matoha’s innovation is seen as a vital
a spokesperson from tool in pushing the fashion industry
Matoha. towards a circular economy. The
UK-based tech startup Matoha has funding round was led by impact-driven
successfully raised £1.5 million in a investors and cleantech supporters.
recent funding round to accelerate Matoha plans to use the capital to
the development of its AI-powered scale production, expand into global
material identification scanners. The markets, and continue refining the AI
funding will support the firm’s mission algorithms that power its scanners.
to make textile recycling smarter, faster, The startup is already working with
and more efficient. recyclers, sorters, fashion brands, and
Matoha’s portable scanners use artificial research institutions across Europe
intelligence and near-infrared (NIR) and beyond. As regulators and brands
spectroscopy to identify material push for more sustainable waste
composition in garments and fabrics management in fashion, Matoha’s AI-
instantly. This breakthrough technology driven material scanners may become
is designed to tackle one of the fashion an essential link in the recycling supply
industry’s most demanding challenges: chain.

32 Sustainability - Precision - Automation - Circularity - Energy April 2025

 C I R C U L A R I T Y

Syre launches gigascale

textile recycling plant
in Vietnam
Harry White

Photo: Syre signs MoU with Binh Dinh Province of Vietnam

with intention of establishing Gigascale recycling

Syre, a next-generation textile recycling automated sorting, fiber identification

company, has announced plans to build via spectroscopy, and depolymerization
a gigascale recycling facility in Binh Dinh, units. The goal is to recover textile-grade
Vietnam. This plant aims to process raw materials at commercial scale and
hundreds of thousands of tonnes of feed them back into the global garment
textile waste annually, with a focus on manufacturing system. The investment
mechanically and chemically recycling is backed by global impact investors
polyester and cotton blends. and sustainability-focused funds, who
see textile recycling as a key growth
The facility is being developed in
frontier. The plant is expected to be fully
partnership with local Vietnamese
operational by late 2026 and serve as a
authorities and global apparel brands
model for replication in other key textile
committed to circularity. Once
hubs.By reducing dependence on virgin
operational, it will be one of the largest
materials and preventing textile landfill
textile recycling plants in Southeast Asia,
waste, Syre’s initiative could significantly
positioning Vietnam as a critical node in
accelerate progress toward a global
the global recycling supply chain.
circular textile economy.
Syre’s approach includes integrating

April 2025 Sustainability - Precision - Automation - Circularity - Energy 33

 C I R C U L A R I T Y

EU mandates separate textile

waste collection by 2025
Daniel Brown

The European Union has mandated including drop-off centers, extended

that all member states establish producer responsibility (EPR) schemes,
separate textile waste collection and sorting facilities. The legislation also
systems by January 1, 2025. This encourages partnerships between local
directive, a component of the EU Waste governments, recyclers, and brands
Framework Directive, marks a major to create circular systems. To support
regulatory milestone aimed at reducing this transition, the EU is funding R&D
the environmental burden of textile initiatives focused on textile sorting
consumption. technologies, fibre-to-fibre recycling
innovations, and digital product passport
Currently, over 5 million tonnes of textiles
systems. Brands operating in the EU
are discarded annually in the EU, with
are being asked to label garments
only a small fraction being recycled.
more transparently and design with
Much of the waste ends up in landfills
recyclability in mind.
or is incinerated, leading to significant
greenhouse gas emissions and resource Industry experts applaud the policy shift
loss. The new directive seeks to change but caution that implementation gaps—
that by enabling better sorting, reuse, particularly in newer EU states—may
and recycling of post-consumer textiles. slow down the intended impact. Still,
the move is seen as a clear signal to the
Member states are now in a rush to
global fashion industry that regulatory
establish national-level infrastructures,
pressure for circularity is intensifying.

34 Sustainability - Precision - Automation - Circularity - Energy April 2025

C I R C U L A R I T Y

Kering launches industry-

first water strategy
Matthew Davis

Kering, the French luxury group behind communities, suppliers, and NGOs to
brands like Gucci and Balenciaga, improve water quality and availability.
has introduced the fashion industry’s
Kering is also integrating water-
first comprehensive water strategy.
related metrics into its Environmental
The initiative aims to reduce water
Profit and Loss (EP&L) accounting
consumption, improve watershed
system to quantify and communicate
resilience, and promote responsible
water-related risks and progress. This
water use across its global supply chain.
initiative aligns with the Science-Based
This bold move comes amid increasing
Targets for Nature (SBTN), making
scrutiny of fashion’s water footprint,
Kering one of the first companies to
particularly in dyeing and finishing
adopt nature-based accounting on
stages.
water. By becoming water-positive by
The strategy rests on three pillars: 2050, Kering aims to not only reduce
regenerative raw material sourcing, environmental impact but also secure
water stewardship in production zones, long-term supply chain resilience.
and consumer-facing transparency. Experts argue that such holistic
Kering plans to establish water strategies are essential as climate
resilience labs in ten key freshwater change intensifies water scarcity,
basins globally by 2035. These labs will particularly in manufacturing hubs like
facilitate collective action with local South Asia.

April 2025 Sustainability - Precision - Automation - Circularity - Energy 35

 C I R C U L A R I T Y

Bangladesh’s textile waste

crisis spurs recycling push
Luke Wilson

Bangladesh, the second-largest apparel are investing in localized recycling

exporter globally, is facing a mounting infrastructure, including mechanical and
textile waste crisis, generating nearly chemical recycling techniques.
577,000 metric tons of waste annually.
Experts highlight that for Bangladesh
The vast majority of this waste
to fully harness the potential of
originates from pre-consumer sources
textile-to-textile recycling, there
like cutting scraps and defective
must be coordinated policy support,
garments. Unfortunately, much of this is
financial incentives, and stronger
either exported at low prices, dumped
buyer-supplier collaboration. The EU’s
in landfills, or incinerated, contributing
due diligence laws and brand-level
to severe environmental degradation
circularity commitments are pressuring
and missed economic opportunities.
Bangladeshi exporters to demonstrate
The domestic recycling ecosystem traceable, low-waste practices. Local
remains underdeveloped due to a efforts are also being bolstered by
lack of investment, technological international NGOs and development
constraints, and limited awareness partners like GIZ and H&M Foundation,
among manufacturers. However, a shift which are funding pilot projects and research
is underway. Industry stakeholders, into scalable solutions. If Bangladesh can
startups, and global investors are now formalize waste collection, invest in scalable
focusing on converting textile waste recycling facilities, and embed circular
into a circular economy opportunity. practices across its supply chain, the country
Notable players like Recycle Raw can position itself as a global leader in
and Broadway Regenerated Fiber sustainable apparel manufacturing.
36 Sustainability - Precision - Automation - Circularity - Energy April 2025
 E N E R G Y

Solar cell fabrics open new

chapter in wearable energy
Oliver Taylor

Photo: Wearable ultra-lightweight solar textiles based on transparent electronic fabrics

he line between fashion and function is forces and first responders are testing
blurring further with the development solar backpacks and vests that power
of solar cell fabrics—textiles embedded communication devices and sensors.
with photovoltaic elements that
In the commercial sector, startups like
generate electricity from sunlight. From
Soliyarn and Powerweave are working
outdoor sportswear to military uniforms
on athleisure garments that integrate
and refugee shelters, the applications
energy storage, GPS tracking, and
of energy-harvesting garments are
temperature regulation. These products
expanding rapidly.
target adventure athletes, logistics
These smart fabrics incorporate flexible, workers, and tech-savvy consumers.
lightweight solar modules laminated or
For the textile industry, solar fabrics also
woven directly into the fabric. Innovations
open doors to a new revenue stream:
in organic photovoltaics (OPVs) and
“functional fashion.” Apparel brands
dye-sensitized solar cells (DSSCs) have
are now exploring capsule collections
enabled fabrics that are washable,
featuring solar accessories, charging
breathable, and capable of producing up
pouches, and commuter-friendly
to 200 mW of power per square meter.
wearables.
For example, a jacket fitted with solar
panels can charge a smartphone in four Read Full
hours of sunlight—particularly useful for Article
remote or off-grid environments. Military

April 2025 Sustainability - Precision - Automation - Circularity - Energy 37

 E N E R G Y

Photo: Compressed-Air Energy Storage (CAES)

China scales up Compressed-

Air Energy Storage (CAES)
Daniel Brown

China, the world’s largest energy provinces, including Jiangsu, Hebei, and
consumer and greenhouse gas emitter, Inner Mongolia.
is rapidly scaling up its investment What is Compressed Air Energy
in Compressed Air Energy Storage Storage?
(CAES), signaling a strategic shift in the Compressed Air Energy Storage is
nation’s renewable energy strategy. The a mechanical storage system that
deployment of CAES, a lesser-known stores energy by using electricity
but highly promising energy storage to compress air and inject it into
technology, is poised to play a pivotal underground caverns or purpose-
role in stabilizing China’s vast and built tanks. When electricity demand
increasingly volatile renewable energy rises, the pressurized air is released,
grid—particularly as wind and solar heated (often using waste heat or
power scale to record highs. renewable thermal energy), and then
This move aligns with China’s broader passed through turbines to generate
commitment to peak carbon emissions electricity. The process is analogous to
before 2030 and achieve carbon a rechargeable battery but operates
neutrality by 2060. As of early 2025, at grid-scale with massive storage
several gigawatt-scale CAES plants potential.
are either under construction or in the Compared to traditional lithium-ion
planning stages across various Chinese batteries, CAES offers several key

38 Sustainability - Precision - Automation - Circularity - Energy April 2025

advantages: storage facility in Asia.
• Long-duration storage (ranging from Strategic Drivers Behind the Surge
4 to 24+ hours) 1. Grid Decarbonization Goals: China
• Lower cost per kWh for large-scale is adding wind and solar capacity at
deployment an unprecedented pace—installing
• High cycle life with minimal over 200 GW of renewable power in
degradation 2023 alone. However, grid integration
• Use of abundant and non-toxic remains a critical challenge due to the
materials intermittent nature of renewables.
CAES is emerging as a viable solution
China’s Latest Breakthroughs for storing excess renewable power
In July 2023, China inaugurated what during off-peak hours and discharging
is currently the world’s largest CAES it during peak demand.
facility—the Zhongyuan Salt Cavern 2. Geological Advantage: China
CAES Plant in Henan Province. Built by possesses vast underground salt
China Energy Engineering Corporation caverns, depleted gas fields, and
(CEEC) and State Grid Corporation, suitable hard rock formations ideal
the plant has a design capacity of 300 for CAES development. This natural
MW/1,800 MWh, enough to power endowment makes it cost-effective and
approximately 150,000 homes for six scalable for the country to implement
hours. the technology.
By early 2025, the project has already 3. Policy Push and Investment: The
demonstrated its ability to reduce peak Chinese government has designated
loads, integrate renewable energy long-duration energy storage as a
from nearby solar farms, and stabilize “strategic emerging industry” under
frequency and voltage levels in the local the 14th Five-Year Plan. Substantial
grid. Engineers estimate it reduces coal subsidies, land-use incentives, and R&D
usage by over 100,000 tons per year, grants have been directed toward CAES
cutting emissions by more than 200,000 and other storage technologies.
tons of CO₂. 4. Energy Security: With growing
Another major development is concerns over energy imports and
underway in Hebei province where a fossil fuel dependency, CAES provides
600 MW CAES plant—backed by China a domestic, safe, and long-term backup
Huaneng Group—is being built inside a system for the grid, improving national
repurposed salt mine, combining deep energy security.
geological engineering with renewable Challenges and Technological
power synergy. Scheduled for partial Innovations
operation by late 2025, it is projected Despite its promise, CAES faces several
to be the largest long-duration energy hurdles:

April 2025 Sustainability - Precision - Automation - Circularity - Energy 39

• Efficiency Losses: Traditional CAES ventures in regions with favorable
systems have a round-trip efficiency geological and climatic conditions.
of 40–60%, lower than lithium-ion Future Outlook
batteries (80–90%). However, advanced According to a report by the China
designs—such as adiabatic CAES, Energy Research Society, the country is
which store the heat generated during expected to have over 5 GW of CAES
compression—can boost efficiency to capacity installed by 2030, representing
70% or higher. around 20% of total long-duration
• High Initial Capital Cost: Building storage capacity. If costs continue to
underground storage caverns and gas decline and system efficiency improves,
turbines requires significant investment. CAES could emerge as a mainstream
However, China’s economies of scale option alongside pumped hydro and
and experience in large infrastructure next-gen battery storage.
projects help mitigate these costs. Furthermore, integration with hydrogen
• Heat Management: Proper production is on the horizon. CAES
integration of waste heat and facilities could be co-located with
renewable thermal energy is essential green hydrogen plants, using excess
for maximizing performance. Chinese renewable energy during compression
firms like Tsinghua Energy and CRRC are to simultaneously produce and store
investing in supercritical CO₂ turbines energy, creating a multi-modal energy
and thermal recovery systems to hub.
enhance CAES system design. Conclusion
Global Implications and China’s aggressive scaling of
Leadership compressed air energy storage
China’s ambitious push into CAES is not signals a transformative phase in its
just about domestic grid balancing—it’s energy transition journey. By marrying
also a bid for global leadership in clean renewable power generation with
tech exports. Just as it leads the world cutting-edge storage solutions, the
in solar panels and EV batteries, China country is not only fortifying its grid but
aims to become a hub for exporting also setting a new global benchmark
CAES systems, especially to countries for energy innovation. As the world
in Africa, South America, and Southeast grapples with the dual challenges of
Asia where large-scale grid storage is decarbonization and energy reliability,
needed but lithium supplies are scarce China’s CAES model could offer a
or expensive. scalable and sustainable path forward—
Companies like China National Energy one powered not just by the wind and
Group and Sungrow Power Supply Co. sun, but by air itself.
are already marketing modular CAES
units internationally and entering joint

40 Sustainability - Precision - Automation - Circularity - Energy April 2025

 E N E R G Y

Sodium-Ion batteries
offer hope for sustainable
power storage
Harry White

In the evolving landscape of energy

innovation, sodium-ion batteries are
emerging as a promising alternative to
lithium-ion, particularly in terms of cost,
resource abundance, and safety. At the
forefront of this movement is Natron
Energy, led by Colin Wessells, which is
pioneering commercial production of providers and commercial building
sodium-ion cells aimed at industrial- operators. With high-temperature
scale energy storage. tolerance and enhanced safety features,
Sodium, unlike lithium, is plentiful these batteries are also ideal for
and inexpensive to source. It can be humid or heat-prone manufacturing
extracted from seawater and salt mines, environments.
reducing geopolitical dependencies The fashion and textile sectors, which
and environmental degradation linked are under increasing pressure to
to lithium mining. Natron’s patented reduce carbon emissions and energy
Prussian Blue electrode chemistry footprints, stand to benefit immensely.
enables fast charging, stable cycling, By adopting sodium-ion storage
and minimal capacity degradation. solutions, manufacturers can ensure
This technology is especially relevant energy security while moving toward
for textile factories, which often face decarbonization.
unstable grid supply or high peak- As ESG mandates grow stricter and
demand costs. Sodium-ion batteries lithium prices remain volatile, sodium-
can store renewable energy generated ion technology is gaining traction.
from solar panels or wind turbines While still in its early adoption phase,
and release it during production experts forecast a 300% increase in
peaks, minimizing reliance on fossil- sodium-ion deployment in industrial
fuel-based backup systems. Natron’s zones by 2030. Natron Energy’s
roadmap includes the opening innovation may thus redefine how the
of a gigafactory in Michigan and global apparel supply chain stores and
partnerships with renewable energy manages power.

April 2025 Sustainability - Precision - Automation - Circularity - Energy 41

 E N E R G Y

True cost of steam: An energy

audit across wet processing
units in south asia
M A Mohiemen Tanim

Steam—The Hidden Cost Center The Dominance of Thermal Load

In the textile and apparel industry’s Energy audits across South Asia’s textile
energy matrix, steam plays a vital but factories consistently show that steam
underappreciated role—especially in accounts for 30–40% of total energy
wet processing units where it powers use, surpassing electricity in cost
dyeing machines, dryers, and finishing intensity in many facilities. Generated
equipment. While electricity gets most by boilers—mostly running on diesel,
of the attention in energy efficiency coal, or furnace oil—steam is distributed
initiatives, thermal energy (primarily across a labyrinth of pipelines to various
steam) often accounts for a larger share wet processing points.
of both energy use and emissions,
particularly in developing markets like Distribution Losses and
Bangladesh, India, and Pakistan. Maintenance Gaps
Most factories suffer from outdated
How Steam Systems Drain Profits
infrastructure:
Silently
» Uninsulated or degraded steam lines

42 Sustainability - Precision - Automation - Circularity - Energy April 2025

» Faulty or absent condensate recovery fired boiler.
systems
Monthly Cost Breakdown:
» Over-designed boilers running below
capacity » Diesel Consumption: ~1,100 liters/day

» Manual blowdown procedures causing » Fuel Cost: ~$36,000/month

excessive purge losses » Boiler Maintenance & Downtime:
Such issues result in distribution losses ~$2,000
of 12–20% and boiler efficiencies falling » Water Treatment & Chemicals:
below 70%, far from the 85%+ levels ~$1,500
cited in equipment brochures.
» Effective cost per ton of processed
What the Data Tells Us fabric from steam input alone: ~$44–
$48/ton
A 2024 multi-country audit (conducted
by sustainability programs like IFC PaCT, In many cases, factories spend
GIZ FABRIC, and independent energy 10–15% more than necessary due to
firms) found the following average inefficiencies—without realizing it.
metrics in wet processing factories:
Recovery Levers and Payback
ndicator Observed Range Industry
Best Practice
Models

Observed Industry Best Factories often overlook cost-effective

Indicator
Range Practice interventions. Based on empirical data
Boiler from implemented projects:
63–72% 85%
efficiency
Condensate
recovery
<45% >80% High ROI Interventions
Flue gas <150°C with Solution Savings Payback
>200°C
temperature economizers Condensate 15–25% fuel <12
Steam loss in recovery saved months
12–20% <5%
pipelines system
Fuel overco-
15–30% 0–5% Flash steam 8–10% latent 6–10
nsumption recovery unit energy months
These inefficiencies translate into captured
$10,000–$25,000/month in excess Boiler 5–8% fuel <1 year
energy spending for mid-size units (25– sequencing reduction
&
40 tons/day), and hundreds of tons of automation
avoidable CO₂ emissions. Economizer 6–10% ~18
on flue gas improvement months
Financial Anatomy of Steam line

Let’s take a factory processing 30 tons Despite the savings potential, adoption
of fabric/day using a 2-ton/hr diesel- remains low due to lack of awareness
and fragmented ownership structures in
April 2025 Sustainability - Precision - Automation - Circularity - Energy 43
many factories. require Scope 1 emission disclosures,
which include on-site fuel combustion—
Electric Boilers—A Paradigm Shift like steam generation. Factories unable
or Niche Fix? to show carbon intensity reduction risk:
Electric steam generators (resistance or » Losing preferred supplier status
electrode types) are gaining traction—
» Disqualification from “green” financing
especially in facilities with solar power
or stable grid access. » Reputational damage in ESG
reporting
Benefits:
Compliance and Financing
» 95–99% thermal efficiency
Opportunities
» No flue gas = zero local air emissions
» Programs like Bangladesh’s BIIDF,
» Easier automation and digital control India’s UDYOG RATH, and Pakistan’s
» Compact footprint NEECA are offering subsidies,
matching grants, or low-interest loans.
ROI Case Study: Electrode Boiler » IFC’s Sustainable Energy Finance (SEF)
Retrofit toolkit also supports energy-efficient
» CapEx: $35,000 steam systems.

» Monthly fuel savings: ~$6,000 Steam Optimization Is No Longer

» CO₂ emissions cut: ~18 tons/month Optional
» Payback: ~2.3 years (shorter with Steam represents one of the most
rooftop solar offsets) under-audited and under-optimized
cost centers in textile manufacturing.
Barriers: The combination of:
» High upfront cost for small factories » Rising fuel prices
» Electricity tariff volatility » Emission compliance pressure
Grid reliability issues in certain zones » Energy inefficiency
» Still, in regions with rising fuel prices » Available technologies
and falling solar costs, electric boilers
…makes this the right time to rethink
are approaching economic parity.
steam.
Strategic Implications for the Factories that embrace energy audits,
Textile Industry invest in recovery, and pilot electrification
will not only reduce costs, but also future-
Buyer & Brand Pressures
proof themselves in an increasingly
Global fashion brands are beginning to sustainability-driven supply chain.

44 Sustainability - Precision - Automation - Circularity - Energy April 2025

 E N E R G Y

Low carbon thermal

energy roadmap released
Jack Thompson

The Apparel Impact Institute (Aii) has According to Aii, industry-wide

unveiled a comprehensive roadmap decarbonization of thermal energy
detailing the textile industry’s transition could reduce emissions by 49% by 2030
to low-carbon thermal energy. Thermal if implemented at scale. However, the
processes, including dyeing, drying, roadmap acknowledges substantial
and finishing, account for more than half barriers such as capital investment
of the industry’s GHG emissions. The gaps, lack of technical capacity in SMEs,
roadmap outlines scalable solutions and and policy inertia in key manufacturing
investment pathways to help stakeholders countries. The initiative is supported
decarbonize these high-energy processes. by global brands and multilaterals,
including Target, PVH, HSBC, and the
Key recommendations include fuel
Clean Energy Investment Accelerator.
switching from coal to biomass and
Pilot projects are already underway in
natural gas, deploying solar thermal
Bangladesh, Vietnam, and India. The
systems, and integrating heat recovery
report urges governments to integrate
technologies. The roadmap also calls for
thermal decarbonization into national
increased adoption of digital process
climate strategies and offer fiscal
monitoring and AI-enabled energy
incentives for early adopters.
management systems.

April 2025 Sustainability - Precision - Automation - Circularity - Energy 45