Issue link: https://viewer.e-digitaledition.com/i/1510018
A s one of the world's largest down apparel manufacturers, Bosideng, based in Taicang, C hina, pro duces OEM products for global brands including The North Face, Patagonia and adidas. In addition, the Bosideng owned- brand is highly regarded in China, with 4000 retail outlets across the country. Design and production focuses on extreme conditions, with mountaineering garments receiving an ISPO Award and China Design for Excellence recognition. Bosideng gear has been to both the South and North Pole in expeditions, and has been worn paragliding across Mount Everest. On the fashion front, international designers including Jean-Paul Gaultier and Kenzo have collaborated with Bosideng. e company recently invested in a "smart" factory to inject a new level of production to its existing manufacturing platform, with flexibility, efficiency and sustainability main assets. ree production lines run, ensuring brands have their own line at any one time, each with the same set-up, laser cutting to begin with and piece preparation. Automatic stitching and sonic stitching are so precise there is very little room for error. e same can be said for the down injection stage, traditionally a messy job; the amount of down per baffle can also be delivered in precision to plus or minus 0.01 gm/2, massively reducing rejects. e traceable down, whether goose or duck, is programmed and zoned according to the design. e difference now is that the down is stored on the lower level and air-sucked up to the down injection box. e process is much cleaner than previously, to the point that even when leaving the smart factory, I didn't have a fiber on me. It also is much less hazardous to the manual workers involved. e automation doesn't eliminate the need for a human based workforce, but it does reduce human error, saves on waste and rejected pieces. Planning is also more precise. is is clear to see at the end of each stage of the manufacturing line through digital dashboards that report on efficiency, energy, performance targets. What's interesting is that manufacturing down garments is much more complicated than alternative garments as it is very much piece work due to the down application, but with this new automation, the supply chain is quicker. Brand logos can be applied to pieces through an automated system, allowing for five times the amount as compared to a human, and again, with little error. In addition to benefiting from resource Savvy Solutions At Bosideng's Smart Factory, an Investment in Automation Pays Off. By Louisa Smith Top: Display showcases styles of Bosideng extreme cold protection systems garments. Bottom: A "Cold Room" features at Bosideng flagship retail store. IN THE MARKET / EURO REPORT (FROM ASIA) 8 • Textile Insight ~ Fall 2023 textileinsight.com