From Reactive To Proactive: Four Ways To Manage Supply Chain Disruptions Before They Happen

TW Special Report

Small to mid-sized manufacturers are facing mounting pressure from unpredictable supply chain disruptions. From fluctuating customer demand to reshoring operations and diversifying suppliers, maintaining efficiency and protecting cash flow have never been more critical.

Global instability, shifting market demands, transportation delays and supplier shortages are no longer rare exceptions; they’re recurring realities. For smaller manufacturers without the luxury of deep financial reserves or massive supply networks, even minor disruptions can have significant ripple effects.

To navigate these challenges, you need more than just reactive strategies. You need proactive, data-driven solutions, and that’s where ERP software proves indispensable.

Four Strategies For Managing Disruptions With ERP

To effectively respond to ongoing supply chain volatility, you must move beyond reactive firefighting and embrace strategic, ERP-enabled approaches. Here are four strategies that demonstrate how ERP can help make informed decisions quickly, maintain optimal inventory levels and ensure timely deliveries — all despite external disruptions.

1. Proactive Demand Forecasting
Accurate forecasting is critical in turbulent markets. ERP systems help by analyzing historical data, seasonal trends and market shifts to anticipate future demand. With built-in scenario planning tools, you can simulate various outcomes and prepare accordingly. This proactive stance reduces the risk of stockouts or excess inventory, stabilizing production and improving cash flow.

2. Smarter Supplier Diversification and Management
ERP supports supplier diversification by centralizing vendor data, including performance metrics like quality, cost and delivery reliability. This makes it easier to assess and compare suppliers, identify risk-prone vendors and onboard new partners quickly when disruptions strike. Automated workflows also ensure consistent communication and streamlined procurement processes, reducing delays and minimizing production downtime.

3. Strategic Reshoring with Enhanced Operational Control
ERP systems enable you to evaluate the full impact of reshoring — bringing production closer to home — by offering insights into total landed costs, lead times and compliance requirements. With visibility into domestic supply chains, your company can coordinate logistics, optimize production schedules and adapt quickly to local market changes. ERP makes the reshoring process more transparent, strategic and sustainable.

4. Dynamic Inventory Optimization
Inventory management is a balancing act, especially during supply chain disruption. ERP software tracks real-time inventory levels, usage trends and reorder thresholds, allowing maintenance of ideal stock levels without overcommitting capital. Features like ABC classification and automated replenishment help prioritize high-value items and avoid shortages, while reducing waste and holding costs.

These strategies show how ERP transforms disruption into opportunity by equipping manufacturers like you with the agility, visibility and control needed to outperform in an unpredictable world.

Case Study: Improved Inventory Accuracy and Reduced Lead Times

Cardinal Systems, a leading manufacturer of in-ground swimming pool components, encountered major hurdles in managing inventory and lead times as the company scaled its operations across more than 300,000 square feet of facilities. Their outdated system and fragmented Microsoft Access database created data silos separating sales and inventory management from accounting. This led to inefficiencies, delays and inaccurate stock levels. Feeling the pressure to better manage their supply chain and any disruptions on the horizon, Cardinal Systems turned to Global Shop Solutions ERP software. The investment quickly paid off and just months after implementation, they achieved:

Improved inventory accuracy,  which enabled Cardinal Systems to respond to supply chain disruptions with confidence. By eliminating manual tracking and gaining a real-time view of inventory, the company could proactively address shortages, avoid overstocking and better align inventory with fluctuating demand.

Shorter lead times,  which helped mitigate delays caused by supplier and transportation disruptions. With faster data entry and clearer insight into parts availability, Cardinal Systems could streamline scheduling, reduce production bottlenecks and accelerate order fulfillment.

Enhanced operational efficiency,  which minimized the impact of disruptions across the production floor. Barcode-driven processes reduced costly errors, accelerated workflows and improved coordination between departments, allowing the company to adapt quickly when supply or demand shifted unexpectedly.

A fully documented workflow,  which protected institutional knowledge and ensured process continuity during times of change. With a consistent and standardized workflow in place, Cardinal Systems was better equipped to maintain stability and performance even as experienced workers retired and roles shifted.

These targeted improvements show how Cardinal Systems used ERP not just to digitize operations, but to build resilience into their supply chain — mitigating disruption, maintaining productivity and preparing for future growth. Download the case study to learn more.

The ERP Advantage

ERP software serves as the central nervous system of your operation. By integrating key business functions — from procurement and production to inventory and customer service — ERP provides the tools necessary to manage disruptions head-on with:

  • End-to-end visibility: ERP offers a complete, transparent view of operations, enabling you to monitor every stage of the supply chain, from raw material sourcing to final product delivery. With clear insights into supplier performance, production status and inventory levels, you can identify potential issues before they escalate.
  • Real-time tracking: Timing is everything. ERP continuously updates data in real time, allowing for immediate response to demand fluctuations, delivery delays and supply shortages. This quick responsiveness can help maintain optimal inventory levels and ensure timely customer fulfillment.

ERP empowers manufacturers to anticipate challenges, respond swiftly and keep operations running smoothly — even amid supply chain disruption.

Take Control Of Your Supply Chain With ERP

In manufacturing, disruptions may be unavoidable, but chaos doesn’t have to be. By leveraging ERP software with powerful features like end-to-end visibility and real-time tracking, you can simplify operations, reduce waste and stay resilient. Whether you’re managing complex supply networks, reshoring production or navigating demand shifts, ERP gives you the clarity and control you need to protect your bottom line.

Editor’s Note: This article was provided by Global Shop Solutions, The Woodlands, Texas

 October 28 2025

Powering Smart Textiles With Body Heat, Sunlight And Movement  

By Ellie R. Gabel

Smart textiles are no longer passive wearables that track steps or monitor vitals. They are transforming into energy-active fabrics capable of generating power on their own. This evolution is driven by a growing demand for self-powered systems in health care and performance wear, where reliability and independence from bulky batteries are critical.

These advanced fabrics open new opportunities for enhanced functionality and improved user comfort by capturing energy from body heat, sunlight or movement. For industry professionals, the shift signals innovation and a redefinition of what these products can achieve in modern applications.

Smart Textiles As Energy-Harvesting Platforms

Smart textiles extend beyond consumer wearables, finding advanced applications in industrial and medical fields where performance and reliability are critical. At their core, e-textiles serve five major functions — sensors that capture data, actuators that trigger responses, processors that handle information, integrated energy supplies that replace bulky external batteries and communication systems that connect devices.

The industry is rapidly shifting from dependence on external power sources to integrated micro-energy systems woven directly into fabrics. Current research is heavily focused on thermoelectric, photovoltaic and piezoelectric solutions, which offer unique pathways to harvest and store energy within these structures.

Harnessing Body Heat With Thermoelectric Materials

Thermoelectric textiles harness the Seebeck effect. They convert temperature differences between the body and the environment into usable electricity, turning heat into a steady power source. Advances in flexible thermoelectric polymers and nanocomposites make it possible to embed this technology into fabrics without compromising comfort or mobility, which creates opportunities for seamless integration into everyday wear.

These materials are already being tested in health care for continuous biosignal monitoring, defense for soldier performance gear and consumer wellness for managing chronic conditions. Research shows that patients using monitoring devices powered by these textiles were 5% less likely to return to hospitals for additional care. The biggest hurdle for the industry lies in boosting power density while keeping them durable, lightweight and comfortable enough for real-world use.

Capturing Sunlight With Photovoltaic Textiles

Photovoltaic (PV) textiles are gaining momentum as researchers integrate organic photovoltaics and perovskite coatings directly into fibers, creating fabrics that capture and convert sunlight into usable energy. Several approaches are being explored, including weaving PV fibers into textiles, laminating ultrathin solar films onto fabric surfaces, and developing dye-sensitized products that remain flexible and lightweight.

These innovations open the door to practical applications such as charging communication devices, powering location trackers, and providing energy autonomy in remote or off-grid environments. However, the industry faces the ongoing challenge of balancing high conversion efficiency with flexibility and long-term stability, which ensures solar-powered fabrics remain functional and durable in real-world conditions.

Generating Power Through Movement

Kinetic energy-harvesting textiles generate electricity when fabrics bend, stretch or compress, producing charge through piezoelectric or triboelectric effects that transform movement into usable power. A hybrid approach combining both methods has shown strong potential, as piezoelectric and triboelectric systems work well under mechanical stress without interfering with one another.

Materials like advanced nanogenerators and electrospun meshes offer flexibility and adaptability for integration into wearable fabrics. These innovations are already being applied in self-charging motion sensors, performance wear for athletes and durable military gear designed for extended field use. However, the biggest challenge is scaling up energy capture to provide enough power for a growing range of connected devices while ensuring the products remain lightweight and comfortable.

Hybrid Approaches and Integrated Systems

Hybrid smart textiles push the boundaries of energy harvesting by combining thermoelectric, photovoltaic and piezoelectric elements to deliver around-the-clock power coverage. For example, layered fabrics can generate electricity from body heat when the wearer is at rest and capture energy from movement during activity, creating a seamless power flow. This innovation carries significant weight in an industry responsible for up to 10% of global carbon emissions, as it highlights how textiles can reduce reliance on external batteries and promote sustainability.

Early prototypes already achieve energy self-sufficiency for low-power electronics, which proves the concept is more than theoretical. The vision is to create smart textiles that act as decentralized microgrids for wearables, capable of powering sensors and devices in a way that aligns with performance needs and environmental responsibility.

Challenges and Industry Path Forward

Before reaching full-scale adoption, smart textiles face several challenges, starting with material-level hurdles such as wash resistance, energy conversion efficiency and biocompatibility. The development of biosafe and less irritating materials is especially critical. These fabrics are designed for continuous use near or directly on the human body, where long-term comfort and safety cannot be compromised.

On the manufacturing side, the industry must solve issues related to scalable weaving processes, fiber durability and overall cost reduction to make energy-harvesting textiles commercially viable. Compliance is also central, with strict safety standards and performance certifications shaping how products move from research labs to the market. The biggest opportunity lies in fostering collaboration among material scientists, engineers and device makers to bridge the gap between technical innovation and practical, real-world deployment.

Smart Textiles Redefining Energy Through Heat, Sunlight And Movement

Body heat, sunlight and motion form the three core pillars driving energy harvesting in smart textiles. They enable fabrics to power devices without external batteries. The convergence of materials science and advanced manufacturing accelerates progress, which makes textiles more functional and sustainable. These forces redefine the role of fabrics, positioning them as active energy systems for the next generation of wearable technology.

Editor’s Note: Ellie R. Gabel is an associate editor at Revolutionized, a digital transformation magazine.

October 28, 2025

Fruit Of The Loom Appoints Scott Daley Senior Vice President – Brands

BOWLING GREEN, Ky. — October 21, 2025 — Fruit of the Loom Inc. announced today that Tony Iannuzzi, senior vice president of Apparel, will retire at the end of the year after an impressive 36-year career with the company. Succeeding him, Scott Daley will join Fruit of the Loom Inc. as senior vice president – Brands, effective November 3. He will report directly to Jeff Cohen, CEO.

In his new role, Daley will oversee brand strategy, execution, and profitability for Fruit of the Loom®, Vanity Fair Lingerie®, Russell Athletic®, and Jerzees® in the U.S. and Canada, as well as Global Spalding®.

“Over his three decades with the company, Tony has played a pivotal role across various departments and with our customers, vendors, and employees alike. His customer empathy, strong leadership, and business acumen have been pivotal to the company’s success. Scott’s experience will build on Tony’s legacy, and we are excited about the future he will build for our brands,” said Jeff Cohen, CEO.

Daley brings nearly three decades of experience from Reebok, where he held a series of leadership roles culminating in his position as general manager for USA. His previous roles included vice president of Global Footwear, general manager of the Running Business, and head of Basketball Products and Apparel. A Boston native, Daley holds a Bachelor of Arts from Boston University and an Executive MBA from Northeastern University

Posted: October 28, 2025

Source: Fruit of the Loom, Ltd.

Microban International Launches Ecofresh Odor-Capture Technology For Active And Outdoor Lifestyles

HUNTERSVILLE, N.C. — October 21, 2025 — Microban International, supplier of odor-control solutions, announced the launch of EcoFresh™, a cutting-edge odor-control technology that captures a wide spectrum of body, environmental and other offensive odorants.

Developed with active and outdoor enthusiasts in mind, this comprehensive technology targets and captures odors on the surface of and within treated fabrics, delivering powerful odor reduction and lasting freshness, even in challenging environments.

EcoFresh captures a diverse set of odorants, including sweat/foot/body odor (carboxylic acids), aging body odor (aldehydes), smoke odor (aromatics), fish odor (amines and sulfides) and more. It provides fast-acting odor capture, working in real time to prevent treated materials from becoming saturated or overwhelmed by odorants. This technology outperforms activated carbon fabrics while offering unmatched fabric types and color options, creating lasting performance and extending use of polyester, polyester-rich blends, spandex, nylon, cotton, nonwovens, polypropylene and more.

“We’re proud to introduce a comprehensive technology that represents the broadest offering in our odor-control portfolio,” said Souvik Nandi, Vice President of Technology & Innovation at Microban International. “EcoFresh is designed to deliver exceptional odor-capture performance for end consumers while ensuring seamless integration for our manufacturing partners across a wide range of applications.”

The EcoFresh technology features two main offerings: EH1000, which is compatible with wicking aids, and ER1000, which is compatible with durable water repellents and customer-added binders. The technology can be applied during normal manufacturing processes, including exhaust, padding and spray applications, with no additional steps required. EcoFresh’s nonionic makeup and customizable compatibility enables use within a range of applications, including activewear, hiking and camping gear, uniforms, filtration and upholstery while preserving the fabric’s original comfort and performance.

EcoFresh is currently undergoing OEKO-TEX® certification and bluesign® approval, marking a key step in validating its performance and commitment to meeting the highest industry benchmarks.

Microban International will debut EcoFresh™ technology at two upcoming events: Performance Days in Munich, Germany (October 29–30, booth H42), and Functional Fabric Fair in Oregon, USA (November 11–13, booth 784). Attendees are invited to visit Microban’s booths to discover how EcoFresh is redefining odor-control innovation. To learn more ahead of the shows, visit https://www.microban.com/odor-control/technologies/ecofresh.

Posted: October 28, 2025

Source: Microban International — Part of Barr Brands International

REI Co-op And Ambercycle Reach Three-Year Agreement To Scale Regenerated Polyester

SEATTLE & LOS ANGELES — October 28, 2025 — REI and Ambercycle today announced a three-year offtake agreement for cycora® regenerated polyester. This agreement will help Ambercycle scale up their production of next-generation materials and advance REI’s commitment to bringing the best outdoor gear to its members while minimizing waste and environmental impact.

Every year, the fashion industry generates over 92 million tons of textile waste, most of which ends up landfilled or incinerated, driving greenhouse gas emissions and resource depletion. Polyester, the backbone of technical and outdoor apparel, makes up roughly 57% of global fiber production — the vast majority of which is still derived from fossil fuels.

As the nation’s largest specialty outdoor retailer, REI is uniquely positioned to help mature the market for regenerated polyester. Many popular REI Co-op brand products contain polyester, including the Magma Sleeping Bag, XeroCloud Rain Jacket, and Road Tripper Duffel Bag. Beyond its own products, the co-op further engages its thousand brand partners to advance more sustainable and inclusive business practices via its Product Impact Standards. Taken together, the purchasing power of the co-op’s customers and members can help mainstream the use of lower-carbon materials across a huge variety of outdoor gear and apparel.

Since 2020, REI has increased fivefold the portion of recycled polyester that goes into its Co-op brand products. As of 2024, over 50 percent of the polyester used in REI Co-op brand products came from recycled sources. This partnership with Ambercycle will help REI build on this progress, while helping “close the loop” by creating new textile products made from waste textile feedstocks.

“At REI, we see next-generation materials as critical to building a decarbonized future for outdoor gear,” said Ajay Chadha, director of Materials Innovation at REI Co-op Brands. “As we work toward our 2030 goals, REI Co-op Brands is investing in science-driven solutions like textile-to-textile recycling to cut emissions at the feedstock level and reduce reliance on virgin polyester. This is one of the initiatives that reflects our long-term commitment to scaling low-carbon materials and delivering real impact for our members and the broader industry.”

This agreement establishes a phased pathway for cycora integration at REI Co-op Brands: initial adoption in priority performance categories, followed by broader material integration as supply scales. In parallel, Ambercycle is expanding molecular regeneration capacity to recapture end-of-life textiles and return them to fabric supply chains — building the backbone of a lower-carbon material system.

REI believes taking climate action creates an incredible opportunity to innovate, enabling us to make products that perform better, last longer, and reduce impacts on the planet. Through its agreement with Ambercycle, the co-op seeks to continue to incorporate innovative low-carbon materials into its products as part of its broader goals to minimize its environmental impact.

“REI’s influence extends far beyond its own brand — as a co-op, it brings together a thousand outdoor brands and millions of members under one vision,” said Shay Sethi, CEO and co-founder of Ambercycle. “That makes them a uniquely powerful partner in scaling decarbonized materials. By integrating cycora, REI is helping to set a new standard for the entire outdoor industry, proving that high-performance gear and circular systems can go hand in hand.”

Posted: October 28, 2025

Source: Ambercycle

Acme Mills Named U.S. Distributor Of Ahlstrom’s New Optipad™: A High-Performance, Sustainable Filter Pad For Extended Cooking Oil Life – Powered By Durafry

BLOOMFIELD HILLS, Mich. — October 28, 2025 — Great Lakes Filters a division of ACME MILLS LLC, a North American manufacturer and converter of high-performance textiles and filtration products, is proud to announce a strategic partnership with Ahlstrom — the global company combining fibers for innovative and sustainable specialty materials.

Pads and envelopes to fit your existing fryers

Acme Mills will serve as a distributor of Optipad™ leveraging its decades of filtration and textile converting expertise to bring this high-value product to market with efficiency and scale.

Optipad is a pre-impregnated filter pad designed to simplify the frying oil filtration process while significantly extending oil life — by up to 50%. Combining advanced fiber-based filtration material, Optipad removes impurities more effectively, improves oil quality, and reduces waste and operating costs for foodservice operations.

Optipad also maintains lower TPM-% (Total Polar Materials) levels for longer durations than conventional methods, ensuring higher oil quality and better-tasting food.

“We’re excited to partner with Ahlstrom to bring Optipad to customers across North America,” said Jim Colman, CEO of Acme Mills LLC. “This product perfectly aligns with our commitment to innovation, sustainability, and delivering smarter filtration solutions to our customers. The ability to extend oil life, reduce consumption, and improve operational efficiency is a true game changer for the foodservice industry.”

Acme Mills offers a full range of converting services, including cut and sew, slitting, sheeting, rewinding, die cutting, and custom packaging. These capabilities enable Acme to deliver highly tailored textile and filtration solutions, providing customers with both performance and convenience.

Posted: October 28, 2025

Source: Acme Mills Corporate Headquarters

Levi Strauss & Co. Unveils Ambitious 2030 Water Strategy To Build Supply Chain And Community Resilience

SAN FRANCISCO — October 23, 2025 — Levi Strauss & Co. (LS&Co.) today released its 2030 Water Strategy – Beyond the Blue, a new roadmap to reduce water use, improve water quality, and help suppliers and communities become more resilient to climate change. The strategy builds on LS&Co.’s legacy of water leadership and is an element of its Climate Transition Plan.

“We know climate change is the existential challenge of our time—and water is where many of its impacts are felt most acutely,” said Michelle Gass, president and CEO of Levi Strauss & Co. “Our 2030 Water Strategy outlines how we’ll continue to lead on water stewardship, not just by reducing our own impact, but by helping build resilience in the places that need it most.”

Three Pillars for a Water-Resilient Future

The 2030 Water Strategy is centered on three key pillars:

    • Improve Our Foundation: LS&Co. will use science-based insights to improve its performance and deepen its understanding of the impacts and dependencies on water and nature. This work will inform how and where the company prioritizes actions in the areas of high-water stress to address the water impact of manufacturing and raw material usage.
    • Reduce Our Impact: By 2030, building on progress made to date, LS&Co. aims to:
      • Reduce absolute freshwater use by 15% across its apparel and textile manufacturing suppliers, compared to a 2022 base year.
      • Ensure 40% of water used in manufacturing is recycled or reused.
      • Publish an open-source industry guide on water recycling and reuse.
      • Ensure that 100% of direct discharge supplier facilities achieve the “Foundational” performance level of water pollution compliance and 25% reach “Progressive” level, as defined by the Zero Discharge of Hazardous Chemicals (ZDHC) Foundation.
  • Foster Resilience: LS&Co. will also:
    • Support suppliers with training and tools to strengthen their water resilience.
    • Launch watershed restoration projects in areas of high-water stress, aligned to its 2030 biodiversity goal, such as the Sutlej and Indus basins in Pakistan and the Meghna basin in Bangladesh.
    • Expand water, sanitation, and hygiene (WASH) projects, including its participation in WaterAid’s Women + Water Collaborative in India, which aims to reach 150,000 people with access to clean water in its first two years.

“A reliable supply of clean water is essential for health, dignity and a life full of opportunity. But 2.2 billion people in the world still do not have access to that life-saving resource. In Levi Strauss & Co., we’ve found a partner that values the power of collaboration to address the water crisis, one of the most challenging, but solvable, problems of this generation,” said Kelly Parsons, CEO, WaterAid America.

Looking Ahead

LS&Co.’s new strategy builds on its current water goals, which run through the end of this year. It also connects the company’s water goals with its broader climate and nature strategies, emphasizing transparency and focusing on the communities most affected by water stress. The targets are aligned with leading global frameworks, including the Science Based Targets Network (SBTN) and the Taskforce on Nature-related Financial Disclosures (TNFD).

“This strategy is about more than water savings — it’s about resilience and supporting business continuity for the long-term,” said Jeffrey Hogue, chief sustainability officer. “We’re working to ensure that our supply chain and the people within it are equipped to adapt to some of the most acute impacts of climate change.”

LS&Co. will report annually on progress toward its 2030 water goals and continue to collaborate with industry peers, NGOs, and local stakeholders to drive systemic change. The water strategy complements other steps the company is taking to build supplier resilience, like its recently launched Energy Accelerator Program (LEAP) in India, which supports suppliers’ transitions to renewable electricity.

“Levi Strauss & Co’s leadership in advancing water availability, quality, and access for communities shows what’s possible through adoption of the Water Resilience Coalition’s Positive Water Impact framework,” said Jason Morrison, Head, CEO Water Mandate and President, Pacific Institute. “Their 2030 Water Strategy embodies the ambition needed for a water-resilient future.”

To learn more about LS&Co.’s 2030 Water Strategy and its sustainability strategy, visit levistrauss.com/sustainability.

Posted: October 28, 2025

Source: Levi Strauss & Co. (LS&Co.)

Thermore® Launches Freedom: The New 100% Recycled Thermal Insulation That Bends, Stretches, And Breathes Like Your Favorite Yoga Pants

MILAN, Italy— October 28, 2025 — Thermore, a global supplier of thermal insulation for apparel, is proud to introduce Thermore® Freedom, a next-generation insulation designed to redefine comfort, performance, and sustainability.

Developed to move with the body in every direction, Thermore Freedom delivers active warmth that’s flexible, lightweight, and responsibly made. It marks a true evolution in performance materials, offering a modern and conscious approach to how we dress and move.

Built on advanced technology and a deep respect for the environment, this insulation is made from 100% recycled fibers, sourced from PET bottles and even reclaimed materials from electronic components like plugs, connectors, and cables. It’s a tangible example of circular economy in action, reducing environmental impact without sacrificing performance.

What sets Thermore Freedom apart is its extraordinary ability to adapt to movement. Its internal structure is made up of micro-gaps — tiny spaces that flex with every movement — so the insulation moves with every step, stretch, and breath, then springs back perfectly to its original shape. The result is warmth that feels natural and unrestricted, maintaining its elasticity and loft wear after wear.

Combining high flexibility with exceptional shape recovery, Thermore Freedom provides consistent comfort even after repeated use. A patented fiber control technology prevents migration, ensuring long-lasting stability and performance. It’s easy to care for (machine- or dry-cleanable) and stands out for its soft hand feel, lightweight warmth, and excellent warmth-to-weight ratio, making it ideal for both technical and lifestyle apparel.

In line with Thermore’s ongoing commitment to sustainability, Freedom is Global Recycled Standard certified.

Available in a range of weights (g/m²), Thermore Freedom meets the needs of brands that value both technical performance and environmental responsibility. With this launch, Thermore takes another step toward a more responsible future — delivering innovative insulation solutions that never compromise on performance, quality, or respect for the planet.

Posted: October 28, 2025

Source: Thermore

Lenze Presents Innovative Solutions For The Modernization Of Textile Machines At ITMA Asia 2025

SINGAPORE/AERZEN, Germany — October 28, 2025 — Lenze, a drive and automation specialist, will be presenting innovative solutions for the modernization of textile machines at ITMA Asia 2025 in Singapore (28-31 October, Hall 7, Stand B201). The focus will be on energy-efficient drive packages, modular machine concepts and scalable software solutions.

Innovations for sustainable textile production: Lenze presents the IE5/IE6 motor drive system at ITMA Asia

The demands for sustainability in the industry are increasing rapidly. Particularly for new systems and modernizations, the focus is shifting to reducing grid connection power and operating costs. Lenze is meeting this global demand with a solution that sets standards: The Motor Drive System IE5/IE6. With efficiency classes up to IE6 and a sensorless control concept, Lenze offers a technology that can be used internationally. The combination of high energy efficiency, simple integration and robust performance makes the system the ideal choice for machine builders and end customers looking for eligible solutions to sustainably reduce their energy costs and CO₂ emissions. Lenze will be presenting this solution at the world’s largest trade fair for textile and clothing technology, ITMA Asia (October 28-31, 2025 in Singapore), in Hall 7, Stand B201.

With innovative drive technology, Lenze is setting new standards in sensorless control of industrial applications. The open-loop control of the IE5/IE6 motors offers a highly efficient solution for applications that rely on high precision. Thanks to a starting torque of up to 300% from 0 rpm and high-resolution rotor position detection, the motors enable exact torque control without

additional hardware. The technology reduces motor losses by over 60% compared to IE2/IE3 and at the same time cuts system costs by up to 50%. The open-loop concept is particularly impressive in dynamic applications such as textile machines thanks to its energy efficiency, robustness and ease of integration.

Impressive performance: 300 percent starting torque (overload torque)

The IE5/IE6 motor drive system enables an overload torque of up to 300% directly from standstill. Starting at full load is reliable and completely without motor feedback — a powerful combination of efficiency and simplicity. This means that the system can be designed more precisely for continuous operation, as it is not oversized, and then delivers the required power immediately.

Lenze offers the new m550 synchronous motor in outputs of 0.25 – 11 kilowatts (kW) and m650 for dynamic applications in 0.75 – 22 kW. Both can be seamlessly combined with gearboxes from the Lenze modular system. Helical, angular or bevel gearboxes are available for a wide range of requirements.

Sensorless and safe

Thanks to the precise control of the m550/m650 synchronous motor, encoderless positioning is possible with the i550. The integrated safety functions such as Safe Torque Off (STO) ensure machine and personal protection. In future, the system will be supplemented with additional encoderless safety functions such as Safe Limited Speed (SLS).

Energy efficiency and transparency included

The solution’s integrated energy recovery system automatically feeds excess energy back into the mains — without any additional hardware. Machine operators also receive high-quality information from the machine sensors via the IO-Link interface and benefit from increased system transparency.

Efficiency meets scalability

The IE5/IE6 motor drive system meets all current and future energy efficiency standards and offers an excellent price-performance ratio. Thanks to the innovative control process, many applications for which servo systems are traditionally used can be solved without external feedback, such as goods transport in the finishing area. This makes the system particularly robust, low-maintenance and cost-efficient — ideal for the requirements of the textile industry.

“Our functional model with two stylized machine elements demonstrates this extremely impressively and dynamically using movement tasks in the area of speed synchronization and positioning,” said Klaus Dierkes. The combination consists of the m550/m650 motors, the g500 gearboxes and the current i550 and i650 inverter generation. The first synchronous motor that is as easy to use as an asynchronous motor.

Future-proof modernization for textile machines – i950 servo drive enables simplified replacement without controller adaptation

The focus will be on the i950 servo drive, which enables a simplified and cost-efficient replacement of 9300 series devices — without interfering with the existing control system.

Lenze thus offers machine operators worldwide a future-proof and economical option for extending the service life of their systems.

Simplified replacement, minimal downtime

The i950 is compact, smart and can be integrated immediately. Thanks to identical Profibus, motor and mains interfaces as well as a compatibility switch, the i950 can fully replicate the behavior of the 9300 servo drive. The PLC software remains unchanged, only the application is transferred and adapted. “Whether replacing a single device or a complete migration project – with the i950, we offer our customers maximum flexibility and investment security,” said Daniel Repp, Product Manager Motion Control at the Lenze Group.

The i950 offers a more compact design than the 9300 servo drive with the same performance and impresses with its lower power loss. Its higher efficiency reduces both energy consumption and heat dissipation in the control cabinet. In addition, the i950 enables future-proof upgrades, for example through motor monitoring via motor currents. This leads to cost-efficient retrofitting and higher system availability.

Global support for OEMs and end customers

Lenze supports OEMs and end customers with customized replacement and migration packages, local support and a global partner network. A worldwide service network ensures that servo drives can be replaced quickly and reliably anywhere in the world. This is particularly relevant for the textile industry because it gives customers, who are spread all over the world, the certainty that they will receive all-round support from Lenze Service or our service partners. “Our customers benefit from short response times, high availability and comprehensive support — from planning to commissioning,” Repp continues.

Live at the trade fair: Migration made easy

At ITMA Asia, visitors can find out how easy it is to convert from the 9300 servo drive to the i950, even with an existing Profibus connection. A step-by- step animation shows the conversion and compatibility settings. This makes modernization for existing systems child’s play.

Modular machine concepts with Lenze FAST Application Software and PLC Designer

Modular machine concepts are becoming increasingly important in textile machinery manufacturing. They enable customized, scalable solutions for different applications and offer advantages in terms of flexibility, efficiency and future-proofing.

The Lenze FAST Framework and PLC Designer 4.0 enable the flexible configuration of machine variants – regardless of the hardware used. This shortens the time-to-market and reduces sources of error in the engineering process.

Increasing efficiency and productivity through automation and digitalization is one of the biggest challenges for companies in the textile industry. Customers need solutions that not only reduce energy consumption and costs, but also respond flexibly to individual requirements and enable seamless integration into existing systems. As a technology leader in the field of motion control for finishing and spinning machines, Lenze is driving innovation.

Open interfaces for seamless integration

Lenze’s automation systems have open interfaces that enable easy integration into OEM ecosystems and the integration of third-party components. End-to- end data access from the drive to the cloud creates transparency and opens up new possibilities for digital services.

Efficient configuration without programming knowledge: More flexibility and shorter time-to-market

The simple adaptation of machine configurations without in-depth programming knowledge accelerates market launch, minimizes sources of error and enables flexible price-performance models. Targeted quotation creation also opens up new potential in sales. Thanks to intuitive configuration options, there is no need to involve specialized software developers. This significantly shortens the time-to-market and reduces the risk of errors in the development process. Adjustments to the machine configuration can be made flexibly and at a later date in order to optimally meet individual customer requirements and ensure an attractive price-performance ratio.

PLC Designer 4.0 makes it possible to create modular software. First, a standard program is created, on the basis of which machine variants can then be derived through configuration. Programming is carried out using function definitions. The hardware selection is independent of this and only becomes relevant at a later stage.

The FAST Framework offers a toolset for programming modular software with automatic error and interface management. The configuration of the individual machine can be derived by selecting the options of the chosen configuration. Customers can select the hardware independently of this, so that a servo system or an open IE5/IE6 package is used, for example, depending on the application requirements.

End-to-end automation platforms with modular software and scalable hardware enable precise control and modification of processes such as yarn spinning, winding, printing or washing in the textile sector. The integration of servo systems, distributed controllers and modular I/O islands ensures high flexibility and productivity.

Posted: October 28, 2025

Source: Lenze SE

VDMA Members At ITMA ASIA + CITME In Singapore

SINGAPORE — October 28, 2025 — With 69 exhibiting member companies, ITMA ASIA + CITME 2025 is once again marked by a strong presence of VDMA companies. Altogether 82 companies from Germany will exhibit at the show, covering about 3,500 square meters of exhibition space, topped only by China and Italy. VDMA initiated a German Pavilion with two group stands (spinning in hall 4 and finishing in hall 7) with a total of 30 exhibitors.

Dr. Janpeter Horn, Chairman VDMA Textile Machinery Association

On the occasion of a VDMA press conference at ITMA ASIA + CITME, Dr. Janpeter Horn, chairman of the VDMA Textile Machinery Association and Managing Director of August Herzog Maschinenfabrik explained: “The geopolitical and economic conditions are currently difficult. This makes the strong presence of VDMA member companies at ITMA ASIA + CITME, which is being held in Singapore for the first time in twenty years, all the more gratifying. The show offers VDMA members a key opportunity to showcase their latest technologies and connect with the ASEAN markets as well as other markets in Asia.”

Dr. Harald Weber, managing director of the VDMA Textile Machinery Association added: “It is no surprise, that most visitors to the ITMA ASIA + CITME shows in Shanghai came from the People’s Republic. My expectations of the trade fair in Singapore are that the audience will be broader. I hope we will see numerous visitors from the ASEAN region, from India, Pakistan and Bangladesh and from the Central Asian countries, just to mention a few.”

Experience leading technology

The VDMA members in Singapore cover nearly all different machinery chapters along the textile value chain including spinning and man-made fibers, nonwovens, weaving, braiding, knitting & warp knitting, finishing & dyeing as well as technologies for textile recycling and processing of recycled material. The companies remain focused on developing innovative, sustainable solutions that reduce production costs while upholding the high standards of European machinery — a commitment captured in their shared slogan in Singapore: ‘Experience Leading Technology’.

Major topics of the show will be automation, sustainability and circular economy. Here are just a few examples of exhibitors that stand for the entire industry:

Automation is a way to address the challenges of labor-constrained textile operations. On display in Singapore is an automation solution for the sliver transport in spinning. The topic of recycling is becoming increasingly important in the textile industry, for example due to corresponding government regulations that are aiming at a circular economy. At ITMA ASIA + CITME a system can be seen, that automatically sorts garments by composition and colour and prepares materials for further processing. It enables the recycling of post-consumer and post-industrial textile waste into fibers for spinning, nonwovens and composites.

Recycling is just one example for the broader topic sustainability. One way to produce sustainably is to make processes more efficient. Sustainable dyeing technologies reduce the consumption of water, energy, chemicals, and dyes while ensuring superior product quality and shorter production times by integrating flexibility and speed. That is another example of how economy and ecology can meet.

Export figures show a mixed picture

Asia has been the number one production location for textiles and clothing in the world and will retain this position for a long time to come. So, it is no surprise that Asia is the most important sales market for the VDMA member companies.

Between January and August 2025, German exports of textile machinery and accessories worldwide summed up to almost 1.2 billion euros, a decrease of 9.5% year-on-year. Half of the exports went to Asia. Nevertheless, a closer look reveals a mixed picture: German exports to China (plus 25%), Pakistan (plus 32%) and Uzbekistan (plus 16%) saw strong increases.

Cautious sales expectations

A survey among the VDMA member companies in the beginning of October showed that 50% of the responding companies assess their current business situation as satisfactory. Around 30% expect the business situation to remain unchanged in 2026, while 60% anticipate a deterioration in business prospects. For the current year, 60% of companies in the textile machinery manufacturing sector expect sales to stagnate. For 2026, 74% continue to expect stagnation. At least 19% of companies anticipate sales increases of up to 20%.

Better sales opportunities in Asia 2026

According to the VDMA survey, the member companies see better sales opportunities in Asian markets for the coming year than in 2025. Southeast Asia, Central Asia and South Asia are rated much better for 2026. These expectations are in line with IMF forecasts, which predict a GDP growth of over 6% for India and growth rates of just over 4% for China and the ASEAN region in 2026.

“The Asian markets are offering great chances that European machinery manufacturers can take with their innovative and sustainable solutions and the high quality of machinery that customers rightly expect. The VDMA members are looking forward to welcoming numerous visitors from various countries to their booths in Singapore”, summarised Dr. Janpeter Horn, Chairman of the VDMA Textile Machinery Association.

A list of all VDMA member companies exhibiting at ITMA ASIA + CITME 2025 is published at www.vdma.eu/itma.

Posted: October 28, 2025

Source: The VDMA Textile Machinery Association

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