How AI and advanced hardware are transforming the textile industry

Some industries are deeply traditional, relying on manual processes that have remained largely unchanged for decades. Transforming these sectors is no small feat.  

In an episode of Automation Caffeine, we spoke with Max Easton, Global Innovation Director at Smartex, about how his company is helping to modernize one such industry: textiles. Their innovative approach combines AI-powered automation with advanced hardware to address inefficiencies, reduce waste, and make the production process smarter and more sustainable.

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A smarter way to make textiles

Smartex integrates AI-powered cameras into fabric production machines, allowing manufacturers to identify and address defects in real time. These cameras take thousands of photos of fabric as it’s produced, using machine learning algorithms to detect flaws like holes or structural defects. The system halts production the moment an issue is detected, allowing workers to intervene before significant waste is generated.

This approach eliminates the need for manual inspection, which is still the norm in many textile mills. By reducing waste and ensuring higher-quality output, Smartex’s solution saves manufacturers money while also improving sustainability. It’s no wonder their system has already been deployed in over 1,000 locations worldwide.

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Tackling long-standing challenges

The textile industry, valued at over $2 trillion, remains heavily reliant on outdated methods. Traditionally, fabric defects have been identified through manual inspection—a process Max described as “a human staring at a moving wall” for hours on end. This tedious work is prone to human error and results in slower production times and wasted resources.

Adopting new technologies in the industry hasn’t been easy. Many mills are family-run, with leadership that tends to be conservative about change. In addition, the industry operates on thin margins, making it difficult for businesses to justify the upfront costs of automation. These challenges, however, are precisely what Smartex’s modular system is designed to overcome. By integrating into existing machines and demonstrating immediate value, Smartex is gradually building trust and driving adoption.

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Turning data into an advantage

One of Smartex’s most impactful contributions is the way it uses real-time data to transform textile production. Traditionally, manufacturers have had to rely on outdated or incomplete information about their operations. The innovation changes that by offering actionable insights based on live data.

With this data, manufacturers can optimize their processes, reduce inefficiencies, and deliver higher-quality fabric to garment makers. It also allows brands and garment manufacturers to track quality and progress, enabling more transparent and efficient supply chains. This transparency is critical as companies face growing pressure to prove the sustainability and reliability of their products.

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Lessons for other industries

The challenges Smartex is addressing in textiles are not unique to this industry. Many sectors struggle with inefficiencies, outdated processes, and a lack of transparency. There are several valuable takeaways other industries here:

1. Start small but impactful. Addressing a single, high-impact inefficiency—like defect detection—can pave the way for broader adoption of new technologies.

2. Focus on modularity. Designing systems that can integrate with existing infrastructure makes it easier for companies to adopt innovations without overhauling their operations.

3. Leverage real-time data. Providing actionable insights empowers companies to optimize their processes, improve quality, and reduce waste, giving them a competitive edge.

Smartex demonstrates how even the most traditional industries can embrace innovation to improve efficiency, reduce waste, and enhance sustainability. By tackling one of the most significant pain points in textile production, the company is transforming the industry and setting a model for others to follow.