A FESPA SmartHUB roundtable at Personalisation Experience 2025 discussed smart manufacturing’s transformative impact on the textile industry. Experts highlighted the shift to on-demand customisation, driven by digital printing, data analytics, and automation. Key takeaways included enhanced machine control, significant waste reduction through intelligent software and colour management, and improved sustainability via energy efficiency and near-shoring, ensuring agility and environmental responsibility in textile production.
Smart manufacturing is transforming industries worldwide, and the textile sector is no exception. At the recent FESPA SmartHUB held in Berlin, a dynamic roundtable brought together industry leaders to discuss how technology is reshaping textile production processes for the better. From on-demand manufacturing and print customisation to sustainability-driven software solutions, the discussions shed light on how advancements in intelligent automation, data analysis, and agile design are driving the future of textiles.
This article explores the key takeaways from the Fespa SmartHUB panel discussion, highlighting impactful examples and expert insights shared by panellists:
- Folker Stachetzki – Marketing – Brother
- Sharon Donovich – Marketing Communications Director – Kornit Digital
- Guy Alroy – Founder, GM – Early.Vision
- Oliver Mustoe-Playfair – Co-founder – Prinfab
- Moderator: Debbie McKeegan – Fespa Textile Ambassador
Whether you’re a textile manufacturer, tech provider, or industry observer, you’ll learn how smart manufacturing is redefining production efficiency, reducing waste, and accelerating sustainability in the printed textile space.
What is Smart Manufacturing in Textiles?
Smart manufacturing involves the integration of advanced technologies such as digital printing technology, data-driven automation, machine learning, and intelligent software to optimise production workflows. For the textile industry, this approach represents a monumental shift from traditional mass production methods to agile systems of customised and sustainable production.
Sharon Donovich from Kornit Digital outlined smart manufacturing as “four pillars”: a move from mass production to customisation, the adoption of advanced data analysis, accurate forecasting, and increased automation. These principles enable textile companies to respond effectively to market demands, lower operational costs, and reduce environmental impacts.
A Growing Shift Towards Customisation: The demand for personalised, on-demand products has grown rapidly over the last six to seven years, altering the dynamics of textile manufacturing. Debbie McKeegan, the FESPA Textile Ambassador, opened the discussion by emphasising the significance of digitalisation in this transformation. She highlighted its potential to empower businesses to meet customer demands whilst also adopting sustainable practices.
Sharon elaborated: “The ability to forecast accurately and produce only what’s needed is the hallmark of smart manufacturing. It’s about agility—not just in production but also in design. Customisation has driven textile companies to shorten production cycles, minimise waste, and adapt to shifting consumer demands.”
Machine Control Enhances On-Demand Production: Accurate machine control is a game-changer for on-demand manufacturing. Folker described how Brother have developed innovative print solutions by building their own machine system tailored for specific production needs. This shift enabled them to achieve a level of precision and flexibility previously unattainable in traditional manufacturing models.
Oliver Mustoe-Playfair of Prinfab also noted that their focus was on “democratising design” through software solutions that enabled scalable on-demand manufacturing. Their ecommerce business model allows end-users to purchase printed textiles on-demand, democratising design and empowering creatives – whilst reducing minimum orders, alongside operational errors and waste. “By automating nesting orders and printing only what’s necessary, we reduce the resources spent on overproduction.”
Reducing Waste Through Technology and Data Analysis: One of the most pressing challenges in the textile industry is waste, and smart manufacturing presents compelling solutions. Industry experts highlighted how AI-powered automation and data analysis are helping manufacturers tackle complex waste issues.
Oliver explained, “Monitoring waste is critical, especially in textile printing. Tracking factors like humidity or defective fabric quality helps address issues before they escalate.” Data recording and analysis not only improve quality control but also provide deeper insights into consumption patterns and production inefficiencies.
Software also plays a vital role in waste management at Prinfab. Having developed their own software tool which uses advanced algorithms to automate order nesting, generating a more efficient use of fabric. Sharon Donovich further emphasised the importance of colour management, explaining, “Accurate colour matching dramatically minimises waste by reducing the need for reprints and adjustments.”
Driving Sustainability Through Smart Systems
Sustainability was one of the central themes of the conversation, with all panellists stressing the growing global push for environmentally friendly practices in textiles. Folker Stachetzki of Brother described their inward focus on minimising chemical and material use while developing energy-efficient machinery. Global legislation and certification requirements are pushing companies to prioritise sustainability in research and development.
Automation also reduces human intervention, aligning production processes with sustainability goals. Sharon underscored this by noting, “Automation saves not only materials but energy, which is critical for making local and sustainable production viable.”
The panellists observed that the COVID-19 pandemic, and geo-instability had further accelerated trends like near-shoring and automation. By placing production closer to end markets, manufacturers can reduce transportation costs and carbon footprints while responding faster to consumer demands.
Leveraging Automation and Simplifying Technology: The future of smart manufacturing lies in automation. Participants agreed that simplifying operating processes to minimise the need for human intervention will be pivotal. Folker highlighted innovations such as QR codes and dedicated pins that optimise machine settings for specific garments, enhancing both precision and usability.
“Software is the backbone of sustainable print and personalisation. By enabling efficiency, reducing waste, and delivering customised solutions at scale, we empower businesses to meet both economic and environmental goals.” – Guy Alroy, Early Vision
Debbie McKeegan remarked, “Simplifying technology is key to agile manufacturing. Printers shouldn’t have to touch the technology to continually adjust settings; they should be autonomous by default using innovative technology.”
Key Takeaways and Future Outlook for Smart Textile Manufacturing
The roundtable discussion made one thing abundantly clear: smart manufacturing is not just an option but a necessity for the textile industry to thrive amid evolving market conditions. Below are the key takeaways:
Shift Towards Customisation: The industry is moving from mass production towards customised, on-demand solutions that reduce waste and allow for shorter production cycles.
Focus on Machine Control: Tailored machinery solutions and automation are enabling unprecedented levels of precision and efficiency.
Commitment to Sustainability: Companies are prioritising waste reduction, resource efficiency, and sustainable innovation.
Critical Role of Software: Intelligent software solutions are helping standardise processes, improve quality, and democratise design.
Adoption of Automation: Autonomous production systems are simplifying complexity, reducing reliance on human intervention, and accelerating local manufacturing.
Smart manufacturing is no longer a concept of the future but a tangible reality driving today’s textile industry. By leveraging print automation, predictive analytics, and sustainable practices, businesses have the opportunity to achieve operational excellence while meeting evolving consumer expectations.
If your business is ready to take the leap into smart manufacturing, consider partnering with technology providers who align with your vision of sustainability and smart solutions. The era of agile production is here, and now is the time to embrace it.
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