A new Gherzi Germany study prepared for VDMA examines how textile processing, cut-and-sew and finishing are expected to evolve through 2035.
Textile World Special Report
The textile industry is entering a new phase of transformation. A new Gherzi Germany study prepared for VDMA argues that future competitiveness in textile processing, cut-and-sew, and finishing will depend less on individual machines and more on integrated, digitally networked production systems.
Building on that thesis, “Threads of the Future,” prepared by Gherzi Germany for VDMA Textile Care, Fabric and Leather Technologies, explores how textile processing, cut-and-sew, and finishing will evolve through 2035.
Its central message is clear: competitiveness is no longer defined by individual process steps, but by how well entire production systems perform as a whole.
From Processes To Integrated Systems
For decades, textile production has been organized as a sequence of largely separate steps — cutting, sewing, finishing — each optimized individually. That logic is now breaking down. Digital connectivity, data integration and automation are linking processes that once operated in isolation into increasingly coordinated production environments.
In this new reality, value is shifting away from process-level optimization toward system-level performance. Cutting systems feed directly into sewing operations, quality inspection loops back into process control, and finishing is no longer the final step but part of a continuous, data-driven workflow. The key question is no longer how efficient a single process is, but how efficiently the entire production chain operates.
Several forces are driving this transformation simultaneously. Traditional growth models built on scale are reaching their limits as overcapacity and pricing pressure reduce the benefits of volume alone. Productivity, flexibility and consistency are becoming the decisive factors. At the same time, production environments are becoming more integrated, with automated cutting, modular sewing solutions and AI-supported inspection increasingly forming connected systems rather than stand-alone applications.
This shift is reinforced by changes in demand. Growth is moving toward technically demanding applications — from automotive and filtration to medical and advanced materials — where precision, traceability and reliability are essential. These segments require tightly integrated processing capabilities and reward solutions that work seamlessly across multiple steps.
Sustainability is adding another layer of complexity. What was once primarily a reporting topic is rapidly moving onto the shop floor. Energy consumption, water usage and material efficiency are becoming measurable and controllable production variables, directly influencing how processes are designed and operated.
At the same time, circularity is gaining momentum. Recycling and material recovery are moving beyond niche applications toward industrial-scale relevance, placing new demands on processing — from sorting and separation, to reintegration into production flows.
Automation, Global Shifts And The Road To 2035
Automation plays a central role in all of this, but with clear limits. In areas such as cutting, inspection and parts of finishing, automation is already well established. Digital workflows, CNC systems and real-time quality monitoring are standard in many operations.
However, one challenge remains unresolved: the handling of flexible materials. Sewing and joining processes are still difficult to automate fully, as textiles are inherently variable and hard to control. While robotics and AI are advancing, full automation remains limited to highly standardized applications. In practice, the most effective production models are likely to remain hybrid, combining machine efficiency with human expertise.
These technological shifts are mirrored by changes in global production structures. Rather than a broad reshoring of manufacturing to high-cost regions, the industry is reorganizing into more differentiated, regionally distributed networks. Established hubs continue to handle large-scale volumes, increasingly supported by automation, while nearshore regions gain importance for flexibility and responsiveness. At the same time, high-value process-ing and innovation activities are strengthening closer to end markets.
For providers of textile processing technologies, this changing landscape brings significant implications. Customers are no longer looking for stand-alone solutions; they expect integrated systems that connect processes, generate data, and deliver measurable performance across the entire production chain. Digital integration, real-time monitoring, predictive maintenance and built-in traceability are becoming baseline expectations.
At the same time, business models are evolving. Alongside physical equipment, software, data-driven services and performance-oriented offerings are gaining importance. The ability to combine process expertise with digital capabilities is emerging as a critical differentiator.
Looking ahead to 2035, textile processing is set to become more flexible, more connected and more intelligent. Modular automation will allow greater adaptability, while AI-supported quality control will increasingly move from defect detection to prediction. Integrated data systems will link design, production and logistics, and sustainability will become an operational discipline —managed continuously rather than reported retrospectively.
What emerges is not a gradual evolution, but a structural shift. Textile processing is moving from fragmented processes toward integrated systems, from labor-intensive production toward hybrid automation, and from linear value chains toward more circular models.
In this environment, success will depend less on optimizing individual steps and more on connecting them. Those who can design and operate intelligent, integrated production systems will not only adapt to the transformation — they will shape it.
TW‘s Quick Take
For textile producers, garment makers and technology suppliers, this study makes one point clear: future competitiveness will depend less on individual machines and more on how well entire production systems work together.
Cutting, sewing, inspection and finishing are becoming part of integrated, digitally networked environments, so equipment and technology decisions must consider connectivity, traceability and system fit, not just stand-alone performance.
— Textile World Editors
Editor’s Note: This report was submitted by VDMA Textile Care, Fabric and Leather Technologies and Gherzi Germany. Textile World edited the text for length, clarity and house style.
2026 Quarterly Issue III
