Kornit systems enables retailers and brands to produce fashion on-demand
A viable solution
The fashion industry is the seventh largest global economy, however to maintain this size, many retailers and brands rely on mass production to produce poor quality, disposable clothing. According to Herbones, 80 billion more garments are available every year and for cheaper than before.
As living costs continue to rise at exponential levels it is no surprise that consumers will opt for cheap prices over more expensive but sustainable options.
What does this have to do with print I hear you ask? Textile print and print-on-demand has the ability to combat this impact and companies such as Kornit Digital and Epson are demonstrating how the industry can use its ever-evolving technology to bring fashion production on-shore, reduce lead times, and produce better quality products that are good for our planet.
Of course, textile printing is far from limited to clothing, it extends to home décor, wallpaper, soft signage such as banners and flags, and much more. In this feature, we outline some of the innovative ways textile print can be used such as for charity and fundraising, and the benefits it can bring to the environment.
Knowledge is power
Very Displays designs and supplies indoor and outdoor display solutions for four main categories: exhibition and events, retail and POS (point-of-sale), textile solutions, and outdoor options. Operating out of its 25,000sq ft warehouse in Leicestershire, Very Displays’ primary focus is supplying trade customers with portable display hardware, however the company also offers large-format printing to help customers when production is at full capacity. This is done using Very’s high-end dye-sublimation machinery and the company also offers sewing and finishing services.
When it comes to textile printing, choosing the right fabric is an important step that can change the look and result of a product. Andy Elliott, sales manager of Very says that the importance of choosing fabric for display products is primarily connected with the peculiarities of production along with what’s most suited to the hardware the printed textile is being displayed upon.
Very Displays offers high-end dye-sublimation printing as well as sewing and finishing services
“If the fabric is printed and finished on the appropriate materials, it will hold up perfectly and look incredible for your customers, keeping them coming back,” Elliott says. “At Very Displays we use a number of textiles such as lightweight material for outdoor flags and stretch polyesters for indoor fabric tube displays, all of which have been vigorously tested for suitability.”
If the fabric is printed and finished on the appropriate materials, it will hold up perfectly and look incredible for your customers, keeping them coming back”
Something Very Displays is finding at the moment is that due to the reusability and more environmentally friendly nature of textile print, customers are opting for larger fabric back walls instead of traditional pop-ups. The company’s Fabric Back walls come in a range of sizes up to six metres making them ideal for events and exhibitions.
Reflecting on considerations sign-makers may need to take before offering textile print services, Elliott adds: “Machinery can be expensive when it comes to printing textiles, so having a skilled team in place is crucial to ensure maximum output.
“Our print manager has 20+ years of knowledge in printing textiles and is supported by artworkers, print operatives, and machinists who have a wealth of experience too.”
Like Very Displays, another organisation that is making use of dye-sublimation technology is West Herts College. The College chose an Epson SureColor SC-F501 to show students how dye-sublimation printing enables on-demand product development which in turn removes the need for international freight shipping.
West Herts College is showing students how dye-sublimation printing enables on-demand product development
Students will use the dye-sublimation printer to create womenswear and menswear as well as to upcycle textiles. The printer will enable the College to educate students on the ethical and environmental issues within the design and production of fashion and how dye-sublimation can help to counter this.
Rehana Khan, lecturer at West Herts College, says: “We wanted to be able to give students an opportunity to see for themselves how digital print can be used in fashion. Now technology has become easier to use, and more affordable, the time was right for us to make that investment. Having access to the latest technology is essential in making students aware of what is possible.
“Students can create their designs and immediately hold their end-product. They can also consider a different approach to garment creation – whether that’s with the production process or the textiles used. It will be the first time they will have used the technology to bring their designs to life.”
Khan explains that the College chose the 24-inch dye-sublimation printer with fluorescent yellow and pink ink because it had a heat press and wanted a dye-sublimation printer that was easy to use, had a narrow width, could manage pattern pieces, and was compatible with the programmes they were already using.
Another way Epson highlights that businesses can combat the impact of the fashion industry is through reshoring. Phil McMullin, pro graphics sales manager at Epson UK says that creating a local vibrant textile community can allow brands and retailers to have increased influence over members of its global supply chain as well as reduce transportation across global supply chains.
“Digital printing technologies can deliver easier to control, quick response capabilities that support local manufacturing,” McMullin says. “They can help reshape the production chain while delivering energy and raw material consumption savings.”
McMullin notes how digital direct-to-garment (DTG) printers have evolved to support the design and completion of printed fabrics after responding to a need for fast and cost-effective textile sample creation. This in turn opens up economic, logistic, and production advantages.
“They print on demand just what is required, adapt or alter designs quickly, and eliminate long wait times by ensuring local production,” McMullin continues. “They use less water and energy and require lower quantities of dyes and other chemicals used in the pre- and post-treatment phases.
“This powerful combination makes digital production attractive to both printers and brands. Epson’s portfolio features a number of DTG systems that support the ability to rethink the way clothing and accessories are manufactured. They include the SureColor SC-F3000 developed for higher volume users who will benefit from its increased productivity with a low total cost of ownership.
Epson offers a Sure-Color SC-F3000 DTG Printer for higher volume users
“There is also the SureColor SC-F2100 that has long been the benchmark of reliable DTG printing.”
Another company that has come up with a way to reduce waste in textile printing is GoCustom Clothing. This solution enables brands to streamline the process of producing printed items through an enhanced platform that enables smart management of print-on-demand products for dropshipping. This allows retailers and brands to create products and link them to their e-commerce stores with integration to platforms such as Shopify, WooCommerce, Etsy, and TikTok.
The order fulfilment is completed by GoCustom Clothing which means retailers can focus their time on marketing and selling rather than ordering stock and managing orders and shipping. According to GoCustom, in 2021 products on TikTok were viewed 4.6bn times with this figure predicted to double in 2022. With this in mind, the GoCustom app connects retailers’ TikTok Shop accounts which allows them to sell products directly to customers without them having to leave the video app.
Angus Mitchell, managing director of GoCustom Clothing, says: “As consumers look more and more for sustainable ways to purchase their clothing, print-on-demand offers retailers a cost-effective solution to produce eco-friendly products at the point of order rather than holding expensive and often discarded stock.
“E-commerce has seen massive growth over the last two years and it’s important for us that we keep ahead of the trends, hence our investment in this enhanced platform and the exciting new dropship integration for the TikTok generation.”
Just-in-time production
Manufacturer of sustainable, on-demand DTG and DTF (direct-to-fabric) print systems Kornit Digital is a company that is right at the front of the sustainability march. The company’s proprietary single-step process delivers pigment-based impressions on a broad array of fabrics with wide colour gamut and photorealistic image quality. This is used to produce durable apparel, streetwear, sportswear, swimwear, accessories, home goods, and custom fabrics at a low cost per print.
Kornit Digital produces on-demand DTG and DTF (direct-to-fabric) print systems such as the Kornit Presto Max
Robert Zoch, global content manager, explains: “Our range of production systems were developed to support the needs of both small print operations and global print fulfillers and brands, with consistent production costs enabling just-in-time production that eliminates wasteful overproduction and empowers producers, designers, and brands with the agility to offer new products and applications as market dynamics and new opportunities demand.”
Kornit’s latest-generation MAX systems incorporate screen, dye-sublimation, vinyl, embroidery, and 3D graphic effects within a single digital production system which enables users to increase their output relative to production footprint.
The company’s KornitX workflow solutions also allow for versatile e-commerce platforms, online design tools, routing of orders, production floor management, and shipping logistics for a fast consumer experience. In addition to this, Kornit’s Konnect dashboard module provides managers with total visibility of production, enabling them to identify any issues quickly.
“Taken in whole, these technologies eliminate barriers between textile concepts and their fulfilment, making nearshore proximity production profitable, giving creators access to unlimited graphic capabilities with little upfront investment, empowering eco-friendly production without sacrificing and transcending challenges associated with vast supply chains, labour shortages, inflation, sudden market disruptions (such as the pandemic economy) and more,” Zoch says.
As well as the environmental benefits mentioned, adding textile print to your business offering can also enable you to tap into extra markets. This was seen during the pandemic when wide-format print providers and sign-makers were able to produce wayfinding signage and graphics for safety information and two-metre distancing.
As the home décor market boomed, sign-makers and printers were also able to offer wallpaper printing and other wide-format products. Textile printing was one of these booming markets and Zoch says that digital print technology empowers producers to shift their business plan from forecast-based to a plan that allows them to reprioritise or reallocate their efforts and resources when new challenges or opportunities arise.
“The perfect example is the sudden need for facemasks and other personal protective equipment when Covid-19 shocked the marketplace. Suddenly, everyone was staying home, which devastated business tied to sporting events, in-person gatherings, schools, and tourism – but there was unforeseen demand for these protective pieces and textile producers using digital technology were positioned to answer that demand.
“Digital means creating at the push of a button, and with everyone connected to the internet and the proliferation of design apps and other tools that beg the people to express themselves in new and creative ways, a production mechanism that needs little setup or forecasting and simply gives the people what they want, when they want it means print-service-providers can survive or even thrive where those limited by slower, analogue, more traditional capabilities struggle.”
According to Fashion Revolution, the number of garments produced annually has doubled since 2000 and exceeded 100 billion for the first time in 2014. What’s more, an estimated 92 million tonnes of textile waste is created annually from the fashion industry. Every second, the equivalent of one rubbish truck of textiles is landfilled or burned globally. On-demand production removes waste from the production process as brands can sell the designs first and then produce only what is required. Digital print enables users to localise fulfilment and eliminate the time and logistical difficulties that can arise with overseas production and ensure low and consistent operating costs.
“When you eliminate minimum order quantities, you eliminate barriers to creators of all types and sizes, which opens entirely new sales channels,” Zoch says. “Digital means answering the sustainable imperative without sacrificing profitability or the quality you offer; in fact, your capabilities only grow by going digital.
“Kornit’s technology gives producers flexibility, adaptability, resiliency, and the consistent, reliable production they need to open new business channels and capitalise on emerging opportunities with the speed, quality, and responsible practices that keep customers returning.”
Back of the net
Any sport fans will be familiar with the sight of sponsorship plastered all over banners, flags, and of course team kits. Roland DG, manufacturer of wide-format inkjet printers has produced the nation’s first football shirt featuring the colours of the top 92 clubs in England and Wales to celebrate the 22/23 football season.
The manufacturer did this using its Texart XT-640 printer demonstrating its colour precision and accuracy. Concept kit designer Andy Slater (aka Xztals) designed the ’92 Club’ shirt which features a combination of over 100 unique colours from each team.
The Texart XT-640 is developed specifically for transfer printing and delivers high print quality and speed on long print runs. Colour quality is achieved through 7-droplet technology with the printer offering 4-colour high-speed printing or 8-colour printing from a wider colour gamut and smooth colour gradients.
This machine is aimed at sportswear apparel, accessories print houses, and soft signage manufacturers wanting to produce high-volume sportwear, fashion, soft signage, interior décor, promotional merchandise, and more.
Stephen Davies, EMEA marketing director at Roland DG, comments: “Launched in time for the highly anticipated 22/23 season and during a very memorable year for football, it is the perfect way to highlight the capabilities of the Texart XT-640, which is specifically designed to provide super quality with vibrant colour technology for sportswear, sports apparel, and sport accessory manufacturers.
“The XT-640’s advanced print control technology produces stunning sharp image quality and brilliant vivid colour. For maximum production, it delivers fine detail and superb contrast at impressive print speeds.”
Branding company Infinity Inc. also recently teamed up with Brentford FC to help raise money for Ukraine. Brentford FC is a client of Infinity Inc. and the branded merchandise and apparel business produced a limited edition T-shirt featuring the bee from Brentford’s club crest in the colours of the Ukrainian flag.
Christian Eriksen, former player for Brentford FC wearing the charity T-Shirt produced by Infinity Inc. to raise money for Ukraine
The garment was produced at Infinity’s production facility in Leeds and was worn by the players in the warmup ahead of their fixture against Burnley FC earlier this year before being launched as part of the club’s retail range. The shirts can be purchased from the Brentford Club Shop with all profits being donated to the Ukraine Appeal. Infinity Inc. supplied all the T-shirts at cost price to help maximise donations.
Darren Cohen, chief executive officer and founder of Infinity Inc., says: “We have been working with Brentford FC for two years and we’ve already done so much work with them, so it’s great to partner up on another project, especially when it’s raising money for such an important cause.
“Our team came up with a really effective design, which we think looked great on the pitch, and this has been reflected in the sales of the shirts. We recently supplied warmup tees for World Down Syndrome Day and War Paint for Men too, so it’s great that clients are thinking of us for their charity events.”
Document solutions company Kyocera recently sponsored Reading FC’s 150th anniversary Gala Dinner and special match shirts. The company was announced as Reading FC’s shirt sponsor back in 2005 ahead of the team’s most successful ever season. Fast forward 17 years and Kyocera reignited its partnership to correspond with the club’s 150th anniversary.
O Factoid: According to a McKinsey & Company report created in partnership with Global Fashion Agenda (GFA), the fashion industry is responsible for about 4% of global GHG (greenhouse gas) O
In celebration of the milestone, Kyocera’s logo also appeared on special Reading shirts for a legends match on Saturday May 21st, 2022. The game saw players from 2005/2006 face off against the Reading team promoted to the Premier League in 2012.
As demonstrated in this feature, textile print provides print and sign businesses with plenty of opportunities, from reducing impact on the environment to saving costs and boosting revenue.
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