Jukis DLL-9000C is described as the worlds first sewing machine which comes with a digital drive mechanism and facilitates data transfer through NFC technology

Juki's DLL-9000C is described as the world's first sewing machine which comes with a digital drive mechanism and facilitates data transfer through NFC technology

Cutting-edge textile processing products including a new technology for dyeing yarns in a more sustainable manner and a digitalised sewing machine set up via a touchscreen or app, were among the most exciting developments at this week's Texprocess trade fair in Frankfurt, Germany.

And fittingly, the four winners of the Texprocess Innovation Award 2017 offered new solutions to make production faster, flexible and more efficient – with or without an operator.

The Awards in the 'new technology' category went to:

  • Sweden-based Coloreel with its Embroline technology that enables basic white thread to be dyed during the embroidery process;
  • Juki with what is said to be the world's first sewing machine that comes with a digital drive mechanism and facilitates data transfer through Near Field Communication (NFC) that uses magnetic field induction to enable communication between devices when they're touched together, or brought within a few centimetres of each other; and
  • Industrial-sewing machine specialist Xi'an Typical Europe for Vetron Trace, a new technology that permits pedal-less sewing.
  • While Dürkopp Adler's online monitoring system for industrial production was the winner of this year's 'new process' category.

Judges included Jürgen Brecht (chairman), Marc Cain GmbH; Alexander Artschwager, German Institute for Textile and Fibre Research, Denkendorf, Centre for Management Research (DITF-MR); Claudia van Bonn, Deutscher Fachverlag GmbH; Iris Schlomski, textile network; and Prof Kerstin Zöll, Lower Rhine University, Department of Textile and Garment Technology.

The Coloreel Technology – Embroline
Sweden-based Coloreel's innovation is its Embroline technology, a stand alone thread colouring attachment for embroidery machines that can be used with any type of embroidery machine without modifications, and enables high-quality instant colouring of basic white textile thread while it is being used in production.

Using only one single thread – instead of up to 16 standard pre-coloured threads on traditional machines – results in vastly increased production efficiency (no re-threading or velocity losses due to thread cuts and needle position changes), drastically reduced thread stocks (as only one base thread per embroidery head and ink cartidges are used), and higher quality embroidery (the reduced need for thread cuts means a minimum of lock-stitches on the back of the textile).

Meanwhile, Coloreel says that by using Embroline the textile industry will lower its environmental impact as it minimises waste, utilises water efficiency and disposes no dye into wastewater. In addition, manufacturers only colour the exact amount of thread they need for each order.

Juki DLL-9000C – Digitalisation of the sewing process
Juki's DLL-9000C is described as the world's first sewing machine that comes with a digital drive mechanism and facilitates data transfer through NFC technology, allowing for numerical entry of key settings through the operation panel so that many manual adjustments are no longer needed.

Meanwhile, the presser foot pressure and needle thread tension have been digitalised, and the optimum adjustment values required to produce high-quality seams can be stored on a material-by-material basis in the machine's internal memory, or externally, and can be reproduced with ease. For sewing plants producing diversified products using different materials, this feature helps achieve stable seam quality without time wasted on manual adjustments.

The DDL-9000C Series not only substantially reduces setup time but also adjusts to the material being sewn. In addition, once the settings are stored in its memory, they can be translated to other machines via USB or NFC connection.

Xi'an Typical Europe – Vetron Trace
Xi'an Typical Europe's innovation is Vetron Trace, a sensor-based technology that permits pedal-less sewing for the first time.

Sensors on the machine track the hand movements of the operator and send the information in real-time to the machine, which in turn regulates its speed accordingly. The company says the lack of a pedal results in huge improvements in ergonomics and safety and removes the risk of unintended machine run.

Meanwhile, the company also says it has room to develop the technology further in the future, including the possibility for the machine to stop automatically should the operator's hand get too close to the needle.

Dürkopp Adler – The digital sewing factory becomes a reality
Dürkopp Adler says its Industry 4.0 production monitoring system links up to 1,500 sewing machines in a network, analysing productivity and the status of each machine, and supplying data in real-time.

Meanwhile, the technology enables remote maintenance access and triggers automatic alarm messages to technicians or managers.

"The first real Industry 4.0 product for sewing machines is easy to instal, fulfils highest security standards and will be hosted by one of the most reliable brands in the industry," the company says.

The Texprocess Innovation Award has been honouring outstanding achievements and new developments since 2011. The winning products are selected on the basis of criteria such as innovation, choice of materials and ecological quality.