INDUSTRY INSIGHT: Leveraging AI Software to Increase Profitability and Scale Agile Print Production - Automate or Get Left Behind
All Apparel Manufacturers face an Urgent Mandate: “Automate or be Left Behind”.
Industry leaders like Super Nova Sports and Ryozo International were struggling with severe pre-press bottlenecks and unsustainable fabric waste. By integrating AI Sublimation Software into their workflows, these forward-thinking business‘s eliminated manual variable data entry, boosted fabric efficiency to over 80%, and reduced delivery times by more than half, establishing a highly profitable, agile, and environmentally responsible production model.
WRITTEN BY FESPA TEXTILE AMBASSADOR DEBBIE MCKEEGAN
Leveraging AI Software to Increase Profitability and Scale Agile Print Production
The Sportswear market is experiencing unprecedented growth. Based on Statista data, and specific to printed or tailored garments, the broader activewear market, which includes customised and printed athletic gear, is now projected to reach over $720 US billion by 2034. With this explosion in demand comes a pressing consumer expectation for mass customisation, sustainable practices, and rapid turnaround times.
All apparel manufacturers face an urgent mandate: automate or be left behind. Industry leaders like Super Nova Sports and Ryozo International were struggling with severe pre-press bottlenecks and unsustainable fabric waste. By integrating AI Sublimation Software into their workflows, these forward-thinking business‘s eliminated manual variable data entry, boosted fabric efficiency to over 80%, and reduced delivery times by more than half, establishing a highly profitable, agile, and environmentally responsible production model.
Over the past few decades, digital textile printing hardware has evolved dramatically. Today, innovations continue to address the markets demand for small scale and industrial level dye-sublimation printing. Technologies – from manufacturers such as: Durst, Mimaki, Epson, EFI Reggiani and MS printing solutions can output anywhere from 30 metres per hour to 600 metres. However, this remarkable acceleration on the production floor has exposed a glaring operational vulnerability: pre-press artwork preparation.
“Without an agile, automated data-handling infrastructure, the benefits of high-speed printing and automated cutting or packing technologies are entirely negated”.
Case Study: On-Demand, Scalable Production Challenges for Sports Apparel
For digital print shops like Super Nova Sports and Ryozo International, the primary challenge was not printing speed, but the heavily manual, error-prone workflows within their art departments.
Producing customised teamwear requires collating massive amounts of variable data - player names, numbers, and sizing - and meticulously mapping this information onto complex garment patterns. Traditionally, graphic designers were forced to manually enter this data and manually nest the resulting patterns for printing.
This archaic approach created three critical threats to the business:
Severe Production Bottlenecks: While printers sat idle waiting for files, highly skilled designers were trapped executing repetitive, low-value data entry.
Unsustainable Material Waste: Manual fabric nesting typically yielded a maximum material efficiency of just 61.07%. In an era where material science and circular economies demand radical waste reduction, discarding nearly 40% of premium polyester and synthetic fabrics is an environmental and financial failure.
Costly Human Error: Manual data handling inevitably leads to misprints, incorrect sizing, or misspelt names, forcing costly reprints that erode profit margins and damage client trust.
The Solution for Production Efficiency
To survive and scale, these manufacturers required a systemic technological overhaul. They implemented AI Sublimation Software - a transformative workflow automation engine designed specifically to bridge the gap between design and high-speed production.
The software integrated seamlessly with the tools their designers already used, acting as an intelligent bridge between Excel data and CorelDRAW or Adobe Illustrator. The solution delivered a holistic approach to automation:
Variable Data Automation: Client orders - containing team rosters, numbers, and sizes - were imported directly from Excel. The software automatically populated this data across pre-graded digital garment templates, eliminating manual data entry.
Intelligent Media Nesting: The system's algorithmic nesting feature automatically arranged the varying garment panels for maximum printer efficiency, replacing the wasteful manual layouts.
Print-Ready Export via Hot Folders: Once the AI optimally nested the designs, it automatically generated print-ready files and routed them to the RIP software, feeding high-speed dye-sublimation printers without human intervention.
These examples of software implementation sit at the heart of a broader, modern tech ecosystem for the industry. When combined with advanced 3D design software like Optitex, Clo3D or Browzwear, alongside high-efficiency sublimation technology, and automated laser-cutting and fulfilment packing technologies, it creates an unbreakable chain of agile, on-demand manufacturing.
The integration of AI Sublimation Software yielded immediate, measurable, and highly lucrative results for both Super Nova Sports and Ryozo International.
30% Reduction in Material Waste: By replacing manual layouts with intelligent algorithmic nesting, fabric efficiency surged from 61.07% to 80.19%. On a standard production run, this saved 1.97 metres of fabric per job. A massive leap forward for both operational profitability and sustainable manufacturing.
80% Time Saved in Pre-Press: Jobs that previously took hours of manual configuration are now completed in mere seconds. The art department was transformed from a business bottleneck into a streamlined production asset.
100% Error-Free Production: Automated accuracy ensured perfect placement and data mapping on every print, entirely eliminating the cost and environmental impact of misprinted garments.
Accelerated Delivery: Early adopters reported reducing overall production and delivery times by more than 50%.
The impact on the human workforce was equally profound. As Zafar Iqbal, Production Manager at Super Nova Sports, noted:
"AI Sublimation Software Plugin has transformed our production line. The automated nesting and personalisation features have saved us countless hours, allowing us to focus on our business. It's an absolute gamechanger!"
This sentiment is echoed by Muhammed Bilal, CEO of Ryozo International, who stated:
"Switching to AI Sublimation Software was the best decision we've made. The cost savings alone are incredible... We feel like we're getting the work of three designers for the price of one."
Preparing for High-Speed Personalisation:
As the sportswear apparel industry sprints toward a highly digital, highly customised future, traditional manual processes are no longer viable. The staggering reductions in waste and production time achieved by Super Nova Sports and Ryozo International prove that AI-driven automation is not just an operational luxury - it is a critical necessity for survival, profitability, and environmental stewardship.
The technological journey does not end here. AI Sublimation are actively developing agentic AI functionalities to further streamline the supply chain. Soon, AI customer service agents will integrate directly with ERP systems, handling client communications via email and WhatsApp to provide instant order statuses, thereby creating a seamless loop from initial inquiry to automated packing and fulfilment.
Now is the time to rethink your production strategy and eliminate the bottlenecks holding your business back.
Visit Fespa Global Expo 2026 in Barcelona 19th-22nd May
To stay ahead in the rapidly evolving world of digital printing and customisation, there is no better place to be than the Fespa Global Expo in Barcelona. From 19th to 22nd May, this premier event will showcase cutting-edge technologies, innovative solutions, and invaluable industry insights, all under one roof. Connect with thought leaders, discover groundbreaking advancements, and gain the tools and knowledge needed to revolutionise your business.
Don’t miss this unparalleled opportunity to shape your future in the print and product personalisation landscape.
Print is no longer defined by the inefficiencies that once characterised it…as advances in production processes and technology have significantly improved its environmental performance.
Taran Rai, Corporate Sustainability Manager at Epson explains why?
The story of what happens when young designers access digital technology is still being written.
What once was a theoretical sustainability goal seems to have shifted into an active regulatory reality.
Is the Textile Market Finally Recovering?
After a difficult few years, there are genuine reasons for optimism. Duncan was candid about the challenges: "The market for textiles has been very difficult over the last three years. I'm not going to hide the truth there. But the tide is turning.“
A profound shift is currently reshaping the sector
Changing consumer expectations demand greater design diversity, faster turnaround times, and sustainable manufacturing practices.
To thrive, interior brands must adapt their supply chains, bringing production closer to the end consumer and moving away from bulk manufacturing.
Digital textile printing offers a definitive solution to these operational bottlenecks.
Digital transformation doesn't announce itself.
It accumulates - one innovation at a time - until an entire industry looks back and realises the ground has shifted beneath its feet. That's precisely where textiles stands today.
The conversations happening now about AI, automation, sustainability, and digital product passports are not theoretical. They are shaping decisions being made on factory floors and in boardrooms right now.
“By leveraging advanced digital textile printing, Marylene Madou has successfully merged traditional craftsmanship with cutting-edge technology. Her approach offers a blueprint for how independent designers can scale their brands globally while maintaining a minimal environmental footprint.”
From Helsinki's printing mill to Paris's Le Marais, discover how Marimekko is scaling a design-led brand with purpose, craft, and bold innovation.
But what makes Marimekko's story compelling is not just its aesthetic legacy?
The textile industry is undergoing a vital transformation. As the insights from Techtextil and Texprocess reveal, the path forward relies on a combination of sustainable hardware, intelligent chemistry, and seamless digital workflows.
From Zimmer's industrial-scale energy reductions and Stratasys's on-demand 3D embellishments, to Kornit's single-step technical printing and the unified digital ecosystems of NedGraphics and Optitex, the tools for change are here. To stay competitive, brands and manufacturers must adopt these innovations, moving away from fragmented, wasteful processes towards a truly connected, circular economy.
Friedmans stands as a testament to the power of combining traditional textile knowledge with forward-thinking innovation.
“Operating from their UK headquarters, Friedmans now serves a diverse array of sectors, including swimwear, dance, entertainment, sportswear, interior decor, prosthetics, and even pet apparel. With a strategic supply chain that reliably serves clients worldwide”
The apparel decoration industry is decisively moving away from isolated, analogue production tools toward connected digital manufacturing environments.
"Kornit’s unwavering commitment to transformative technology continues to disrupt the status quo. For business leaders and innovators ready to capture the future of apparel manufacturing, the path forward is clear”
The Urgent Need for Sustainability at Scale
The transformation at Coats provides a vital blueprint for the wider textile and apparel sector. True sustainability cannot be achieved in silos. As Dearing emphasised:
“Cross-industry collaboration is the engine of meaningful change. Brands, machinery suppliers, chemical providers, and fibre producers must act as an interconnected ecosystem”
Today’s customers demand superior product quality, real-time data visibility, and lightning-fast turnaround times.
For large-scale garment decorators, managing these expectations while balancing seasonal demand fluctuations - such as the massive surges seen during Black Friday - presents a monumental challenge.
"Relying on transactional vendor relationships and outdated legacy equipment is no longer sufficient to secure long-term stability and growth.”
Printing method is never a secondary detail. It shapes the entire life cycle of a product, from concept to customer. In today’s fashion industry, where margins are tighter and speed matters more than ever, technical knowledge has become a competitive advantage.
“The future of textile design belongs to professionals who can combine creativity with execution, aesthetics with practicality, and vision with production reality”.
Are we witnessing the reinvention of Merch driven by adaptive, digital technologies?
The commercial opportunity presented by printed, personalised merchandise is already a lucrative revenue stream; it is the core driver of growth in a multi-billion-pound industry. And the mandate for print businesses is clear: automate, adapt, and offer undeniable added value, or choose to gradually lose market share.
Powderless DTF is an important area of innovation. It deserves research, investment, and thoughtful development.
“But at its current stage, it often feels like the industry is attempting to commercialize the concept ahead of the underlying chemistry and system readiness”.
All Apparel Manufacturers face an Urgent Mandate: “Automate or be Left Behind”.
Industry leaders like Super Nova Sports and Ryozo International were struggling with severe pre-press bottlenecks and unsustainable fabric waste. By integrating AI Sublimation Software into their workflows, these forward-thinking businesses eliminated manual variable data entry, boosted fabric efficiency to over 80%, and reduced delivery times by more than half, establishing a highly profitable, agile, and environmentally responsible production model.
The Future of Manufacturing belongs to those who Embrace Connected Digital Ecosystems
“Whether you produce garments, car interiors, or home furnishings, the transition from creative concept to production-ready product often remains fragmented. Design teams work tirelessly to develop compelling materials, yet technical teams struggle to interpret these visions without losing data along the way.”
The European digital wallcovering marketplace is expanding at an impressive rate.
“For print professionals and interior designers, this transition presents a distinct set of challenges. Achieving flawless colour consistency, managing complex substrates, and meeting stringent environmental standards are no longer optional extras; they are fundamental requirements for commercial success.”
If you're looking to optimize your website for AI search, hang onto your cowboy hat. It's the Wild West out there. Former (and current) SEO companies see the handwriting on the wall as more search moves from traditional SEO to AEO (answer engine optimisation). Opportunists are popping out of the woodwork.
(There are good options out there, but vet them carefully.)
A swimsuit might start life as a sketch. By the time it reaches the shop floor, dozens of hands have touched it - designers, dye houses, printers, trim manufacturers, quality controllers. Each one interprets colour in their own way, under their own conditions, with their own tools. The result is often a product that looks nothing like the original vision.
Green Bay, Wis. — August 2026 — BW Converting will introduce textile manufacturers to the capabilities of its Baldwin TexCoat® G4 precision spray finishing system at the 33rd Apparel Sourcing Show, taking place Aug. 18–20 at the Tikal Futura Convention Center in Guatemala City.
The company will participate through its local agent, Maprimaq, at booths 25 and 26.
Soyang Europe, a leading manufacturer and distributor of digitally printable wide-format and superwide-format media, surface coverings and advanced print production hardware solutions, has underlined its long-term commitment to its partnership with Platinum Technologies LIYU by making a major investment in new customer facilities and technical expertise.
Frankfurt am Main – August 2026 – Heimtextil, the world's leading trade fair for home and contract textiles, is set to reveal its highly anticipated Trends 27/28 forecast in a digital live premiere on 7 September 2026 at 14:00 (CEST).
Developed in collaboration with the internationally recognised design platform Alcova, the event will explore one of the most defining tensions in contemporary living: the home as both a space for performance and a place of retreat.
Nanjing – China - August 2026 - The company’s integrated solution portfolio combines digital printing equipment, high-performance printing consumables, and workflow integration to help print providers improve production efficiency across DTF, UV, and sublimation applications.
Driven by shorter production runs, growing demand for personalized products, and increasing sustainability requirements, the printing industry is transitioning from traditional analog production toward more intelligent and integrated digital manufacturing systems.
Hanrun Paper, a global digital printing solutions provider, helps drive this transformation by integrating hardware, consumables, and production workflows into a more connected, efficient, and flexible digital manufacturing ecosystem
Leicester – UK – August 2026 - VeriVide Limited, a leading authority in colour assessment and quality control, has announced the availability of the NCS Exterior Fan Deck, a comprehensive colour tool designed specifically for outdoor environments.
Comprising 322 carefully selected colours, the Fan Deck is tailored for professionals working across architecture, landscaping, property development, and exterior product manufacturing.
Dorking UK – August 2026 – The FESPA Foundation has announced a landmark initiative to unite the global print community under a shared commitment to education, sustainability, and meaningful social impact.
Guided by its "Print for Good" principle, the Foundation is calling on industry stakeholders worldwide to contribute to a movement that positions print as a force for lasting, positive change.
Telford, UK – August 2026 – China Print Supplies UK Ltd today features the availability of the Graphtec CE8000-130 1300mm Vinyl Cutter Plotter, a high-performance cutting solution designed to meet the demands of the sublimation, sign writing, and sticker and label creation markets.
Priced at £3,495.00 + VAT and backed by a one-year warranty, the CE8000-130 represents a significant step forward in cost-effective cutting plotter technology.
Gaziantep, Turkey – August 2026 – Zimmer Austria, in partnership with ERA, is continuing its installation of a Colaris machine at Plato Halı, one of Turkey's leading carpet manufacturers.
This marks the 13th Colaris machine to be installed in Gaziantep, with mass production expected to commence shortly.
Following its successful market launch at the beginning of the year, Felix Schoeller has now received the 2026 Pinnacle Award for RubyPaper in the “Technology” category.
Each year, the PRINTING United Alliance presents the award to pioneering innovations in the printing industry.
This year, a total of 154 entries from 54 companies were submitted for the Pinnacle Award.
Felix Schoeller is one of just 15 companies that entered the competition with a product for the first time and received an award straight away.
North Bergen – NJ – August 2026 – Roland DG Europe has announced that Coach USA's Perfect Body successfully produced 25 FIFA World Cup bus wraps using the TrueVis XP-640 wide-format printer, running operations up to 16 hours a day during one of the company's most demanding production seasons to date
Greentex, a leading innovator in sustainable printed fabrics, has announced its participation in Printing United 2026, taking place from 23 to 25 September at the Las Vegas Convention Center.
Building on the momentum of last year's event, Greentex will debut an immersive booth concept themed "Garden Casino," offering attendees a distinctive way to explore the company's latest fabric collections.
New York, NY – August 2026 – X-Rite Pantone, the global authority in colour standards and colour science, and the Fashion Institute of Technology (FIT), a global leader in creative education and part of the State University of New York (SUNY), have announced a strategic partnership to advance colour education and digital innovation across the apparel, footwear, soft goods, and textile industries
St Laurent – Quebec – August 2026 – Inkcups, a leading manufacturer of printing equipment and inks, has published a new customer success story featuring Spector & Co, a prominent promotional products supplier.
The case study highlights how Inkcups' direct-to-object (DTO) printing technology is enabling Spector & Co to meet the growing demand for premium, retail-inspired promotional products.
Altrincham – Cheshire – August 2026 – Friedmans, a leading fabric printing specialist today festures its new Printed Solids service, designed to help garment makers achieve perfectly coordinated fabrics across a range of bases.
The service addresses one of the most persistent challenges in garment construction: matching plain fabrics, such as nylon, with coordinating stretch nets and other materials.
Las Vegas, NV – August 2026 – Durst Graphics has announced its participation in PRINTING United Expo 2026, taking place from 23–25 September in Las Vegas.
The company will use the event to present its latest advances in digital printing, software, and finishing solutions across multiple booths in partnership with key industry players.
Visitors can find Durst Group at Booth C1614, where the P5 Series will be on live display.
The showcase will highlight the practical applications of three flagship systems: the P5 350 CORE, the P5 350 HS, and the P5 350 HSR —
Lewisville Tx – August 2026 – Antigro Designer has announced the successful integration of its Sticker Builder tool into the Decals On Demand product page, operated by KRP Group USA.
The integration eliminates the need for customers to leave the Shopify storefront or engage in lengthy email exchanges, streamlining the entire custom decal ordering process into three simple steps.
Birmingham, UK – August 2026 – Epson UK & Ireland has announced its sponsorship of the inaugural Print Award for Best Wide Format Project at this year's The Print Show, taking place at the NEC Birmingham from 29 September to 1 October 2026.
The new award category recognises excellence in wide format print and reflects the growing importance of this segment within the broader print industry.
Frankfurt, Germany – 4 August 2026 – Heimtextil, the world's leading international trade fair for home and contract textiles, has announced the launch of 'Comfort & Connect', a new dedicated area for high-quality bed, bath and lifestyle collections.
Located in the foyer of Hall 5.1, the space will serve as a central meeting point for established brands, returning exhibitors and international buyers.
The new area marks the second targeted expansion of Heimtextil's Bed, Bath & Living offering, following the success of the 'Sleep & Meet' format.
Dorking – UK – August 2026 – The FESPA Awards 2027 are set to open for entries, inviting print and signage professionals from around the world to showcase their finest work on the industry's most prestigious global stage.
With an early bird deadline of 31 August 2026 and a final entry deadline of 2 December 2026, the call is clear: the time to prepare is now
London – UK – August 2026 – Vivid Technologies has announced that its flagship product, Razar, has been shortlisted in the Manufacturing category of the prestigious Stationers' Innovation Excellence Awards 2026.
The nomination recognises Razar as a standout example of forward-thinking innovation within the manufacturing sector.
Clay Cross – August 2026 – Resolute DTF has announced it will take a prominent stand at The Print Show 2026, held at the NEC Birmingham from Tuesday, 29 September 2026.
The company will also maintain a presence at The Sign Show, which is co-locating with the event, marking a significant dual appearance for the brand at one of the UK's most anticipated print industry exhibitions
Regensburg, Germany – August 2026 – OneVision has announced the release of software version 26.2, marking a significant step forward in intelligent print automation.
The update introduces new artificial intelligence capabilities, expanded Variable Data Printing (VDP) functionality, and enhanced production monitoring tools designed to help print service providers increase efficiency and output quality.
Version 26.2 introduces a suite of AI Services that seamlessly integrate GPU-accelerated artificial intelligence into existing print production workflows.
SOUTH NORMANTON, UK – August 2026 – Sun Chemical has announced that its Xennia Sapphire pigment inks for digital textile printing have received three of the industry's most sought-after regulatory certifications: GOTS (Global Organic Textile Standard), ECO-PASSPORT, and ZDHC (Zero Discharge of Hazardous Chemicals).
The achievement positions Sun Chemical as a frontrunner in sustainable and compliant digital textile printing solutions.
London UK – July – 2026 – British digital fabric printing company Prinfab has been commissioned to produce a commemorative tea towel to celebrate the landmark birthday of iconic English fashion designer Sir Paul Smith.
Manchester – August 2026 – Premier Digital Textiles today highlights its 2555 Dimout, a versatile, dual-purpose fabric designed to bridge the worlds of fashion and interior design.
With its distinctive silver finish and subtle sheen, the fabric is positioned as a premium material for designers and makers operating across both industries.
2555 Dimout features a smooth silver surface that lends itself naturally to elegant occasionwear, flowing garments, and bold statement pieces.
Its fluid drape and refined aesthetic make it particularly well-suited to summer collections, where lightness and visual impact are equally valued.
Oswestry – Shropshire – August 2026 - Fujifilm Ink, the UK-based global supplier of UV inkjet technology, has strengthened its partnership with China Print Supplies UK Ltd (CPS), becoming the recognised ink supplier for the company's range of Dlican UV printing systems.
The partnership follows the successful rollout of Fujifilm Ink's thermoforming flexible ink technology, reinforcing the company's commitment to delivering high-performance, application-specific ink solutions for the wide-format print market.
Birmingham, UK – July 2026 – swissQprint UK is set to exhibit at The Print Show 2026, taking place from 29 September to 1 October at the NEC in Birmingham, Great Britain.
Visitors can find the swissQprint UK team at Stand P420, where they will have the opportunity to experience the company's latest flatbed printing technology firsthand.
Paris, France – August 2026 – Optitex and NedGraphics will present their integrated design and manufacturing solutions at Première Vision Paris, taking place from 1st to 3rd September 2026 at Parc des Expositions, Paris Nord Villepinte, France.
Visitors can find the companies at Booth 3L11 in Hall 3, Smart Creation Area.
The joint appearance marks a significant opportunity for textile brands and manufacturers to experience first-hand how NedGraphics and Optitex deliver a unified workflow — one that connects textile design, colour refinement, and end product development within a single, seamless process.
Emmerich am Rhein, Nordrhein-Westfalen – August 2026 – Brother Industrial EMEA has announced the launch of its GTX300, a hybrid direct-to-garment (DTG) and direct-to-film (DTF) garment printer that the company says sets a new benchmark for textile print quality.
To mark the occasion, Brother Industrial EMEA is offering eligible print professionals across the EMEA region a complimentary demo package to experience the printer's capabilities firsthand.
FREMONT, CA. August , 2026 – Fiery, a global leader in digital printing technology, has announced the launch of a new free online course designed to help print professionals master colour management for direct-to-film (DTF), direct-to-garment (DTG), and UV printing workflows.
The course, Fiery Specialty Production 301 v1: Colour Management Basics in Digital Factory, is now available on Fiery's learning platform at no cost.