Printed
October 30, 2024
With operations in Los Angeles and Vietnam, Saitex’s industry-leading round manufacturing mannequin now produces over 20,000 pairs of denims in a single day, working with manufacturers resembling Madewell, G-Star Uncooked, Everland and Polo Ralph Lauren. FashionNetwork.com talks to founder Sanjeev Bahl concerning the agency’s newest developments and California’s new laws on textile waste.
Sanjeev Bahl, founding father of Saitex – DR
FashionNetwork: Why are you acknowledged because the cleanest denim manufacturing unit on this planet?
Sanjeev Bahl: Sustainability isn’t only a field we verify—it’s embedded in all the things we do. We recycle 98% of the water we use, harness photo voltaic power to cowl 25% of our energy wants, and guarantee zero discharge of dangerous chemical compounds. On high of that, we’re turning waste into alternative by recycling denim fibers again into new clothes. It’s not nearly being the cleanest manufacturing unit; it is about redefining what accountable manufacturing appears like for the complete {industry}. We collaborate with world manufacturers to push these improvements additional, proving that sustainability and scale can go hand in hand.
FNW : What’s the story of the manufacturing unit in Vietnam? How did it develop to turn out to be a benchmark for trend firms?
S.B: Once we began in 2001, the objective was easy—construct a facility that represented the way forward for accountable manufacturing. Since then, we’ve pushed the boundaries by investing in inexperienced chemistry, renewable power, and cutting-edge water recycling applied sciences to create a very closed-loop system. Truthful Commerce, LEED, bluesign and B Corp, —aren’t simply certifications; they mirror our deep dedication to each the surroundings and humanity. At this time, Saitex Vietnam is greater than a manufacturing unit and mill; it’s a mannequin for manufacturers around the globe who wish to embrace circularity and carbon-neutral manufacturing.
FNW: Why did you arrange a brand new manufacturing unit within the US?
S.B.: Increasing to the U.S., and particularly Los Angeles, was about far more than simply bringing manufacturing again. We noticed an enormous alternative to create a hub that delivers speed-to-market whereas sustaining the very best sustainability requirements. The U.S. is a key participant within the push for round trend, and being near our companions right here lets us innovate sooner, reply to market developments extra effectively, and lower down on waste. It was additionally about bringing jobs again to the West Coast with a concentrate on accountable, scalable onshore manufacturing. That is the way forward for manufacturing—sustainable, agile, and native.
Automated stitching at Saitex’s Los Angelese manufacturing unit – Saitex
FNW: Have any manufacturers stopped manufacturing in Vietnam and relocated to Los Angeles?
S.B: It is extra about balancing proximity and sustainability. Vietnam stays a key a part of our operations, particularly for larger-scale manufacturing, however our Los Angeles manufacturing unit presents agility and the power to supply with minimal environmental affect proper right here in america.
FNW: Your manufacturing unit in Los Angeles has been designed because the manufacturing unit of the long run. What are the particular options of the machines and applied sciences used within the manufacturing unit?
S.B: A manufacturing unit of the long run is one that may reply to the fast-paced modifications in trend by being agile, adaptable, and environment friendly. We’ve constructed a system that may shortly scale up or down manufacturing in response to demand, decreasing the dangers of overproduction and waste. Our on-demand manufacturing mannequin permits manufacturers to check new designs in small batches and produce them to market shortly with out compromising sustainability. We use automation and AI, we’ve got real-time information monitoring throughout each step of the manufacturing course of. This provides us the power to make knowledgeable selections on the fly, adjusting our manufacturing schedules, supplies, and processes as developments evolve. All the pieces is monitored in real-time by our digital platform, guaranteeing we optimize useful resource use and decrease waste at each stage. Our factories are designed not simply to scale back our environmental affect however to actively prepared the ground in versatile, sustainable manufacturing for the way forward for trend.
FNW: Are you able to inform us extra about Saitex’s Pace to Market and SAI Digital?
S.B: Pace to Market is our on-demand manufacturing mannequin centered on small batch manufacturing. It allows manufacturers to supply solely what is required, decreasing overproduction and waste. That is complemented by SAI Digital, our digital arm, which presents superior e-commerce and information options to assist round commerce particularly. Collectively, they type a system that not solely delivers merchandise extra effectively but additionally promotes sustainable and clear practices with our manufacturers from design to distribution.
The manufacturing unit of the long run with moist ozone washing expertise – Saitex
FNW: Among the many applied sciences on supply, the one-step wash machines hook up with a water recycling system. What’s it precisely? How do you handle to recycle water and cut back waste at that time?
S.B: Our one-step wash expertise integrates water recycling on the core of the method. Water utilized in denim washing is handled, purified, and reused a number of occasions, decreasing the necessity for contemporary water by 98%. This technique is a important component in minimizing waste and aligns with our broader objective of working a closed-loop manufacturing course of the place nothing goes to waste.
FNW: Are you able to give us an concept of the water financial savings achieved over a 12 months’s manufacturing?
S.B: On common, we save roughly 500 million liters of water yearly throughout our operations. That is equal to the water consumption of 25,000 households in a 12 months. Our water recycling applied sciences, mixed with our progressive manufacturing processes, be certain that each drop is used effectively.
FNW: What precisely do SB 707 laws impose on Californian trend manufacturers in the present day? And what are the implications?
S.B: SB 707 requires California producers to take duty for the end-of-life administration of their textiles, that means manufacturers should have interaction in textile assortment, recycling, and reuse programs. At Saitex, we’re already main the best way with our closed-loop programs and round manufacturing mannequin, which align seamlessly with these laws, serving to manufacturers meet these new obligations. Certainly one of our key options is Stella Pop, which up-cycles textile waste into practical merchandise resembling inside panels, furnishings, and garment trims. This not solely reduces waste but additionally demonstrates how manufacturers can remodel discarded supplies into purposeful, progressive gadgets.
3D dimensional type ending at Saitex’s Los Angelese manufacturing unit – Saitex
FNW: What new developments are you engaged on in the present day to be much more environment friendly?
S.B: We’re continuously innovating. Proper now, we’re specializing in increasing our use of recycled materials, growing new biodegradable supplies, and enhancing our digital infrastructure for much more exact useful resource administration. These developments will assist us cut back waste additional and scale round manufacturing globally.
FNW: Are you continue to planning to develop a manufacturing unit in New York?
S.B: We’re exploring the potential of opening a brand new facility in New York, however for now, our focus is on optimizing our Los Angeles and Vietnam operations. As we proceed to develop, increasing to different areas will at all times be guided by our sustainability objectives and the demand for accountable manufacturing nearer to key markets.
Lengthy Highway Media
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