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The industry is ever evolving, with new products and innovations pushing the boundaries. But in sustainability and automation, DTG is heading the way to progress; as Folker Stachetzki, marketing manager of Brother, explains.
In today’s rapidly changing world, sustainability and automation have become essential drivers in the textile printing industry, shaping how companies respond to environmental, economic, and technological challenges.
Companies that aim to remain competitive in the long term cannot afford to ignore these trends. Sustainable production processes help conserve resources, reduce costs, and meet the rising expectations of consumers, who increasingly prioritise environmentally responsible products. Simultaneously, automation enables more efficient order processing, fewer manual errors, and shorter production times. Together, these developments allow businesses to act responsibly while improving operational efficiency – a combination that is rapidly becoming a prerequisite for success in the modern printing industry.
DTG printing: Leading in sustainability
Direct to garment (DTG) printing is emerging as a clear leader in sustainable textile production, offering considerable advantages over traditional screen printing and DTF (direct to film) methods. Traditional screen printing requires a separate screen for each colour, which must be coated, exposed and washed after every print run. This process consumes large volumes of water and a variety of chemicals, including emulsions, cleaning agents, and solvents. DTG eliminates the need for screens entirely, cutting water usage by up to 90% and significantly reducing chemical consumption. Moreover, energy requirements are lower, as the process avoids energy-intensive drying and curing steps inherent in screen printing.
Another major sustainability benefit of DTG lies in the use of water-based, eco-friendly inks, which are often GOTS, or Oeko-Tex certified. These inks are free from harmful solvents and heavy metals, making them safer for both workers and the environment.
In contrast, DTF relies on PET transfer films and powdered adhesives. These materials are single-use, generating significant plastic waste, and the powder coating and curing steps consume additional energy, increasing the process’s overall environmental footprint. By avoiding these materials and steps, DTG dramatically reduces both plastic consumption and electricity usage, offering a cleaner, more resource-efficient production model.
Print on-demand and local production
DTG also excels when combined with print on-demand (POD) production. Unlike traditional methods that require producing large batches in advance, POD ensures that textiles are only created when a customer places an order. This approach prevents overproduction, reduces excess inventory, and minimizes waste. Businesses can respond swiftly to market trends and individual customer preferences without compromising sustainability or profitability.
Additionally, DTG enables decentralised, near-customer production, which shortens transport distances and reduces CO₂ emissions. By producing closer to the point of sale, companies not only cut environmental impact but also improve supply chain efficiency and delivery speed. The combination of POD and local production demonstrates how DTG can simultaneously meet sustainability goals and business needs.
Automation and workflow software
Another critical factor in maximising efficiency and sustainability is the integration of workflow software. Modern digital production management systems link e-commerce platforms, order processing, and print preparation into a seamless, automated workflow. Orders can be automatically verified, print files checked for errors, and production triggered with minimal human intervention. This reduces mistakes, shortens lead times, and ensures consistent quality.
When paired with AI-assisted color management and automatic material adjustments, these systems further enhance sustainability. Errors and misprints are minimised, decreasing wasted materials, energy, and labour. Automated workflows also free up staff to focus on value-added tasks, increasing overall operational efficiency and profitability.
A future-oriented solution
Together, DTG printing, print on-demand strategies, local production, and advanced workflow automation provide a holistic approach to sustainable textile printing. Companies adopting these practices can significantly reduce their environmental footprint while improving flexibility, speed, and product quality. DTG represents a shift toward production models that balance ecological responsibility with economic performance – a model increasingly demanded by both consumers and the industry itself.
In a market where sustainability, efficiency, and personalisation are key drivers, DTG combined with automation offers a future-proof solution. By embracing these technologies, textile producers can position themselves at the forefront of innovation, meeting today’s challenges while preparing for the demands of tomorrow.
