WEKO’s technology significantly enhances textile dyeing and finishing processes
Established in 1953, Weitmann & Konrad GmbH & Co. KG (WEKO) is a German family-owned company renowned for its pioneering work in non-contact minimum application systems for fluid and powder-based media. Headquartered near Stuttgart, with production sites in Germany and Brazil and global sales and service offices, WEKO has long been a trusted technology partner across multiple industries—including textiles, paper, plastic film, and nonwovens.
In the textile sector, WEKO is advancing sustainability and efficiency by significantly reducing water, energy, and chemical use through its innovative spray application technology. With growing environmental concerns and regulatory demands, WEKO’s solutions are increasingly relevant to manufacturers aiming to align with circularity and regenerative practices. In this exclusive interview with Fibre2Fashion, Jayanta Sanyal, Head of Technical Sales and Processes – Textile Industry at WEKO, discusses the key sustainability trends, the challenges of modernisation, the role of the WEKO Technology Center, and how the company’s latest innovations are helping transform textile production for a greener future.
What are the key technological trends currently shaping the future of textile manufacturing, and how should companies prepare to stay competitive?
The key technological trends currently shaping the future of textile manufacturing include:
- Sustainable manufacturing and green practices, encompassing energy efficiency, water conservation, reduced use of dyestuffs and auxiliaries, adoption of renewable energy, and effective waste reduction and control.
- Emphasis on the circular economy.
- Integration of artificial intelligence in development, design, and production.
Companies must play a significant role in preparing for and adapting to these changes to stay competitive. The textile manufacturing sector must urgently adopt sustainable production and consumption practices. This requires investment in research and development, and the adoption of circular economy principles. A circular textile framework reduces resource inefficiency and environmental impact by promoting innovative design, integrating new technologies and renewable materials, enhancing garment reuse and recycling, and eliminating waste and pollution.
What are the key sustainability challenges currently facing the textile industry, and how is the push for circularity and eco-conscious production shaping technical innovation in machinery and application systems?
The textile sector faces significant sustainability challenges, including the overconsumption of resources such as raw materials, water, dyes, auxiliary chemicals, and energy. It also contributes to environmental degradation, particularly through water pollution during dyeing and finishing processes, and struggles with waste management due to the generation of hundreds of tonnes of post-consumer textile waste. This waste contributes to growing landfill and incineration issues. Additionally, social and labour concerns persist, especially in developing countries, with problems such as low wages, poor working conditions, and exploitative labour practices. The complexity of global textile supply chains further complicates the tracking of environmental and social impacts, making ethical sourcing difficult to ensure.
Circular textiles refer to an approach in textile manufacturing and usage that aligns with the principles of the circular economy. The industry is currently facing a critical challenge, with projections suggesting it could account for up to 50 per cent of global CO2 emissions by 2030. In light of these alarming figures, the textile industry must urgently shift towards more sustainable production and consumption models.
The growing emphasis on circularity and eco-conscious production is driving technical innovation in machinery and application systems. This includes advancements in fibre production and processing, low-impact dyeing and finishing technologies, and improved textile recycling solutions—all aimed at reducing environmental harm and increasing resource efficiency.
WEKO is known for its contactless minimum application technology. How does this innovation specifically benefit textile production processes, both in terms of efficiency and product quality?
WEKO’s groundbreaking non-contact minimum application technology significantly enhances textile dyeing and finishing processes. Microdroplets, emitted from the efflux edges of rotary atomisers, travel towards the textile web with specific kinetic energy, which is absorbed without any physical contact.
This enforced contactless application ensures the following product and process performance benefits:
- No tailing caused by bath contamination, resulting in consistently higher fresh quality.
- No disruption to the chemical equilibrium of the bath, which is typically affected by continuous fluctuations in concentration during traditional padding processes.
- Elimination of centre-to-side variation.
- The option for single-sided application where required—for instance, applying hydrophobic chemistry solely to the outer surface.
- Precise and accurate application volumes tailored to process or shade requirements.
- Reduced application quantities lead to lower drying energy consumption, decreased water usage, and minimal chemical waste due to reduced drainage.
WEKO’s systems reportedly reduce water usage by up to 80 per cent. Could you elaborate on how your technology supports sustainable textile manufacturing and aligns with global environmental goals?
The traditional dip-and-nip method used in padding mangles has significant limitations due to its high pick-up rates—ranging from 55–65 per cent in woven fabrics to over 100 per cent in knitted fabrics. This excessive moisture must be evaporated during the drying phase, which increases energy consumption and CO2 emissions, contributing to air pollution and a rise in ambient temperatures.
WEKO’s application systems support sustainable textile manufacturing by significantly reducing the application rate to 15–35 per cent. Additionally, they minimise or even eliminate drainage losses caused by bath contamination—a major contributor to water waste in conventional processes. This results in substantial water conservation and energy savings.
Global environmental objectives for sustainable textile production focus on reducing environmental impact and promoting a circular economy, addressing key concerns such as climate change, biodiversity loss, and pollution. WEKO’s reduced application technology aligns closely with these goals, offering a responsible and efficient alternative to conventional finishing methods.
What role does the WEKO Technology Center play in validating applications for the textile industry, and how does it contribute to process optimisation before full-scale implementation?
The WEKO-Technology Center plays a vital role in supporting customers by establishing the foundational elements needed for well-informed investment decisions. In response to enquiries arising from exhibitions, meetings with WEKO sales managers, webinars, seminars, or articles published in print and digital media, the Technology Center carefully analyses each request and requirement.
It conducts liquid tests to evaluate the customer’s specific chemistry and assess the feasibility of spray applications. This is followed by practical spray trials on the customer’s fabric using the Pilot Line—usually in the customer’s presence. In addition to validating existing applications, the Technology Center also develops new processes or formulations, offering recommendations to enhance fabric performance.
This hands-on approach enables customers to observe and analyse results directly on their own materials, fostering confidence to shift from conventional production methods to the WEKO approach.
How has the textile industry responded to the adoption of WEKO’s fluid and powder application systems, particularly in regions where water and energy conservation are critical?
Over the past seventy years, WEKO has been manufacturing and supplying fluid and powder application systems across various industrial sectors, including the textile and nonwovens industries. While WEKO’s powder application systems are not yet specifically tailored for textile applications, innovative development concepts for this sector are currently in progress.
Starting with moisture management in compacting and sanforising processes, WEKO has established successful collaborations with several European OEMs, resulting in a global success story. Building on this foundation, the company expanded its portfolio to offer retrofit solutions for the machinery of direct customers. In response to growing interest and demand, WEKO also introduced chemical applications, followed by innovations in various finishing techniques and also in denim slasher dyeing as well as cotton and polyester fabric dyeing.
Today, as water and energy conservation become critical factors in sustainable manufacturing—with brands and retailers placing increasing emphasis on these areas—WEKO is experiencing a surge in interest in its technologies. Users are adapting rapidly and often returning with repeat orders, reflecting growing confidence and commitment to sustainable production practices.
What are the biggest technical or operational challenges you encounter while integrating WEKO’s solutions into existing textile production lines?
Retrofitting any system into an existing manufacturing line can be challenging. However, WEKO’s compact design allows for easy installation near or above the padder, enabling a straightforward bypass of the padder and smooth integration of the WEKO process route.
The primary operational challenges lie in encouraging and training users on the new system. Some degree of unlearning and relearning is necessary. Manufacturers are often hesitant to deviate from established finishing and colour standards, as well as from familiar washing behaviours. Additionally, buyers may be resistant to accepting new standards that result from changes in the production process.
How do you see WEKO’s technology complementing emerging regenerative practices in textiles?
WEKO offers innovative and alternative sustainable technologies that align well with emerging regenerative practices in the textile industry, working collectively to address environmental impact and resource depletion. The global textile sector faces significant cost pressures, largely driven by the extensive use of fresh water, energy, and chemicals. As a solution, WEKO introduces cutting-edge technology that combines more sustainable processes with cost-effective production, supporting the industry’s transition towards regenerative and responsible manufacturing.
Given WEKO’s presence across multiple industries like paper, plastic film, and nonwovens, are there any cross-industry learnings or technological insights that have informed your approach in the textile sector?
Each industry has its own unique characteristics, as do their production processes. However, the fundamentals of continuous production lines share certain similarities. As a result, the knowledge and experience gained in one industry can certainly help to address challenges in another.
In WEKO’s experience, insights from the paper, plastic film, nonwoven, and wood industries have proven valuable in developing solutions for textile manufacturing. For example, the WEKO ProTec system—originally developed for the nonwoven industry for the application of hazardous chemicals— is now widely used in textile mills for similar purposes.
How does WEKO ensure consistent, high-quality technical support and innovative solutions for its textile clients globally, particularly in key hubs like India, Bangladesh, Indonesia, and Türkiye?
WEKO provides comprehensive global support to its customers through multiple channels:
- Via WEKO’s subsidiaries and agencies in various countries, staffed with trained and experienced sales and service teams.
- Through the WEKO Service Department in Germany, which offers assistance either remotely or by dispatching service engineers.
- Through the Product Management and Technical Sales departments, which provide support via telephone, virtual meetings, and on-site customer visits.
- In addition to the usual communication channels, WEKO is creating another possibility for contact and taking a step towards the digital future. The new WEKO Service App offers the customers and agencies fast and simple remote support for commissioning, updates, trainings, system checks, troubleshooting, installations, and spare part services.
Our agencies actively support customers in key markets such as India (Fab India Technologies Pvt. Ltd.), Bangladesh (Mazim Corporation), Indonesia (PT Agansa Primatama), and Türkiye (Erkim Temsilcilik ve Ticaret Ltd.).
Looking ahead, what key innovations or upgrades can we expect from WEKO in the textile segment over the next few years?
Since its establishment in 1953, WEKO has consistently focused on minimal application methods, offering a more sustainable alternative to conventional technologies. The R&D department at WEKO is continually developing new user-friendly features for its machines and introducing advanced application equipment.
In parallel, WEKO’s process engineers are actively innovating new dyeing and finishing processes that leverage spray technology. These include continuous polyester dyeing (disperse and pigment), digital print preparation (primers), indigo dyeing, single-side spray coatings, and more.
