The printed fashion industry faces disruption from demands for sustainability, efficiency, and customisation. Smart manufacturing, leveraging DTF, DTG, and Roll-to-Roll digital printing, is the solution. Driven by on-demand production, it uses optimised software, automation, and “premiumisation” to boost profitability. Success requires investing in reliable equipment, comprehensive training, and streamlined workflows, making smart manufacturing a present necessity for competitive advantage.

The fashion and apparel manufacturing industry is undergoing seismic disruption. With the growing demand for sustainability, efficiency, and customised printed production, it’s clear that yesterday’s solutions won’t cut it in today’s competitive market. Smart manufacturing technologies, particularly for Direct-to-Film (DTF), Direct-to-Garment (DTG), and Roll-to-Roll digital textile printing, are leading the charge in reimagining how the industry operates and how it serves its customers.

At the recent FESPA Smart Hub in Berlin, industry leaders including experts Marc Verbeem from Mimaki, Joao Sa of ROQ,  George Benglopoulos of PolyPrint, and Jayson Tompkins of Stahls shared their insights into how smart manufacturing technology is reshaping the way printed apparel and textiles are produced. Drawing from these thought-provoking discussions hosted by Debbie McKeegan the Fespa Textile Ambassador – this article explores the opportunities, challenges, and actionable strategies to adapt your business for this transformational era.

The Paradigm Shift to Smart Manufacturing

The transition from traditional methods like screen printing to digital solutions is driven by shifting consumer demands and operational inefficiencies. Customers increasingly expect quicker turnaround times, smaller production runs, and greater customisation. This presents a unique challenge for manufacturers who need to balance speed, efficiency, with quality and profitability.

Joao Sa from ROQ described the industry’s move towards smart manufacturing as a natural response to these changing market dynamics. “For many brands, introducing digital printing technologies has reduced setup times, enabled on-demand production, and facilitated smaller batch orders. Digital solutions, such as ROQ’s first full DTG platform, have also allowed businesses to move from high-volume, one-size-fits-all models to more agile and personalised workflows”.

Key Drivers of Change:

  • On-demand production has become a necessity as customers demand greater flexibility.
  • Operational efficiency is critical to remaining competitive in a high-cost, high-demand environment.
  • Environmental sustainability is no longer optional; consumers expect brands to adopt eco-conscious practices.

Solutions Driving Smart Manufacturing

Smart manufacturing leverages advances in automation, artificial intelligence, and software solutions to streamline processes. Here are the game-changing technologies and strategies highlighted by the panel:

1. Optimised Software for Workflow Efficiency: Jayson Tompkins from Stahls identified software as the backbone of modern printing operations. “Custom software solutions can help resolve inefficiencies and automate processes like job scheduling, production tracking, and quality control”.

For example, on-demand production is at the heart of efficiency in smart manufacturing. Using advanced software, printers can effectively manage single-item production as well as bulk orders. Jason explained how integrating robust digital tools has helped circumvent the challenges posed by market shifts and tariffs, enabling businesses to respond quickly to sudden pivots in demand.

2. Automation to Minimise Labour and Errors: Labour shortages across the industry have made automation more important than ever. George from PolyPrint noted that “automation not only minimises manual errors but also frees up human resources for higher-value tasks like creative design and customer interaction.”

PolyPrint’s latest innovation, their DTF (direct to film) system, incorporates a highly automated process designed to enhance efficiency while maintaining impeccable quality. These systems provide single-step solutions that eliminate multi-process setups, saving time and cutting down on wastage.

3. Premiumisation for Profitability: The concept of Premiumisation (a new word), explained by Joao from ROQ, involves adding higher-end products to a portfolio to capture better margins. For instance, incorporating metallic finishes, luxury materials, or limited-edition designs can justify higher pricing and attract premium customers.

“Premiumisation works best when combined with automation and customisation, as it allows businesses to offer unique products without significant increases in operational costs”.

Overcoming the Challenges of On-Demand Manufacturing

Marc from Mimaki highlighted the hurdles businesses face when adopting on-demand manufacturing. These include handling multiple technologies, navigating the learning curve associated with digital solutions, and the need for stable, reliable systems.

One key takeaway from the discussion was the importance of having a strong support system, both from suppliers and within internal teams. Without proper training, employees may struggle to maximise the value of smart technologies. Mark also stressed the necessity of optimising production workflows to ensure that all stakeholders—from designers to operators to end consumers—can collaborate seamlessly.

Steps to Tackle Challenges:

  • Invest in reliable equipment and robust support systems from trusted suppliers.
  • Provide comprehensive training for your staff to bridge the knowledge gap.
  • Standardise processes and adopt a common digital “language” across all technologies for smoother integration.

Embedding Sustainability into Profits

Sustainability has evolved from a buzzword into a business imperative. The use of eco-friendly inks, reduction of resource wastage through automation, and adopting lean manufacturing principles were cited as the cornerstones of sustainable apparel production.

Automated solutions not only minimise labour inefficiencies but also reduce material waste, energy consumption, and carbon footprints. For instance, effective colour management tools ensure that correct quantities of ink are used, cutting down on both waste and unnecessary costs.

Looking Forward

The future of the fashion and apparel industry is undoubtedly digital, automated, and sustainable. To remain competitive, businesses must rethink their workflows, invest in smart solutions, and adapt to the new demands of on-demand manufacturing. Here’s a summary of actionable insights to get started:

Actionable Takeaways for your Business

  • Adopt Digital Printing Solutions to enable flexibility and customisation.
  • Integrate Automation to reduce operational inefficiencies and production times.
  • Optimise Workflow with Software that enhances collaboration and efficiency.
  • Invest in Training to equip your teams with the skills needed for smart manufacturing.
  • Prioritise Sustainability to meet modern consumer expectations and improve ROI.

By rewiring your workflows to align with smart manufacturing practices, you’ll unlock newfound profitability and remain ahead in the competitive landscape.

The insights shared by thought leaders at the FESPA Smart Hub make one thing clear: Smart manufacturing is no longer the Future; It’s Today’s Necessity. Act now to keep your print operations ahead of the curve. Your competitors won’t wait, and neither should you.