The Economic Downturn and the Textile Industry

It seems that the state of the economy is top of mind for just about everyone these days.  We hear a lot about how the economy has affected the auto industry, the housing industry, etc.  But the reality is that it is impacting just about every industry in the U.S., including the textile industry.

U.S. textile mills have been struggling against the influx of goods from textile mills in other countries, particularly India, Pakistan and China, for quite awhile now.   According to EconomyWatch, in 2007 production in U.S. textile mills fell by more than 12 percent.  ABC News reported that, from October 2007 through October 2008, about 100 textile mills in the U.S. closed, leading to the layoff of over 63,000 U.S. textile workers.  Now, with the downturn in the economy over the last six or eight months, things may be getting worse.

While the emphasis in these articles is on apparel textiles, the import of foreign textiles as well as the struggling U.S. economy has hit the U.S. textile industry as a whole, including those mills that specialized in theatrical fabrics.  We have certainly seen a trickle-down effect, but the most significant impact that I have seen over the last six to twelve months is on availability:

• Longer lead times.  In the past, it might have taken two weeks for milling, while now it may take four or six weeks.  I cannot say definitively the reason for the longer lead time, but I would guess that it is due to a smaller workforce (layoffs).
• Less In Stock.  Many of the large fabric suppliers are stocking fewer fabrics than they were a few years ago.  They just don’t want to tie up as much money in inventory, so they are waiting for firm orders before sourcing the fabric from the mill.  For suppliers with multiple stocking locations, they may stock some fabrics in one location only, rather than in several locations across the country. 

 So what does this all mean for the end-user – the school or church wanting new custom stage curtains or the rock band wanting a new custom backdrop?  In many cases, it may mean making a choice between waiting longer to get their drapery or choosing a different fabric that is readily available.  It may mean paying a higher price for a drapery due to the cost to bring the fabric in from a location out of state.  The best thing I can recommend is, be flexible and plan ahead!

Is there such a thing as a “Green” ink for digital printing?

As I continue to explore the question of eco-friendly textiles, I have been thinking about digital printing. As more and more artists become interested in protecting the environment, we have begun to have more requests for “green” custom band backdrops.  We already have some eco-friendly options available for the fabric substrate, but what about the inks used in digital printing?  UV Curable, Water-based, EcoSolvent, Mild/Light Solvent, Full Solvent – which is best, ecologically speaking?

I would assume (based on the name) that a great choice for digital printing would be to use eco solvent inks.  The reality, however, is that these inks aren’t nearly as ecologically friendly as the name implies.  In researching eco solvent inks, I learned that they contain HAPs (Hazardous Air Pollutants) and VOCs (Volatile Organic Components).  Maybe eco solvent inks are better in comparison to other types of solvent inks, but that doesn’t mean they are good for us.

I’m interested in a new type of ink being touted by EFI – Bio-Solvents.  According to a white paper by EFI, bio-solvent Inks “contain no harmful VOCs and have the best health and environmental profiles available”.  EFI does make a bio-solvent ink (BioVu), so they aren’t exactly an unbiased source.  However, their literature does display the Environmental Protection Agency’s DfE logo, so I am feeling more confident (though I will continue to research this new category of inks before making a decision).

If this is all true, then bio-solvents may be the wave of the future.  Right now, EFI’s BioVu inks are only available for use with one printer type – EFI’s VUTEk 3360 product line – but they say that they have plans to roll it out to other product lines in the future.  I’ll keep my eyes out for it and let you know.

Direct Print vs Dye Sublimation – What’s the difference?

One of the products we offer is custom digital backdrops – the customer supplies the artwork as a digital file, and we print the artwork onto fabric or mesh and then sew it into a fabulous backdrop.  Yes, sometimes for the tours of major recording artists like Kenny Chesney, but many other times for a school or church production or a special event or…

There are the two primary methods of digital printing – direct print and dye sublimation.  In many cases, customers ask, what is the difference between the two?  What makes one method better than another?

Well, here is a very basic primer on the topic.  With Direct Print, the inks are printed directly onto a coated fabric substrate.  Due to the coating, the backdrop tends to be slightly stiffer.  With Dye Sublimation, a paper transfer process is used to convert the ink solid into a gas, which then “etches” the image into the fabric.  As the fabric substrate is not coated, a dye sublimated backdrop tends to be a little softer and more flexible.

So, which is better?  Depends on the individual project.  Direct print can be printed onto fabric up to 16’ in width, allowing larger seamless backdrops or fewer seams on an extra large backdrop.  Dye sublimation, on the other hand, can only be printed onto fabric up 10’ wide, meaning anything bigger would require seams.  However, the image tends to have better resolution and color vibrancy.  Not sure what would work best for your project?  We can help find the right print method and substrate to meet your needs and your budget.

Yes, the Show Did Go On for the Pussycat Dolls

After making a fabulous appliquéd, beaded and dye sublimated satin custom backdrop for the Pussycat Dolls’ current tour with Britney Spears, we had to do some repairs in one day and then ship the drop via Fed Ex International Priority Overnight to the show in Toronto.

Well, Fed Ex really dropped the ball, and it looked like the backdrop wasn’t going to make the show.  After hours on the phone with Fed Ex, I finally learned at 3:30 pm Toronto time that although the backdrop was ready at the Fed Ex Toronto hub, Fed Ex wouldn’t deliver it that day.

That put me in a panic.  The backdrop had to get to the Air Canada Centre by 5:00 pm to make that night’s show.  I jumped on the Internet, and after a couple of false starts, found City Centre Courier.  Mike Kovatch really came through.  With just 40 minutes notice, he was able to get a courier to the Fed Ex hub and through 20 miles of rush hour traffic to the venue.  The package arrived precisely at 5:00 pm and the show went on!  Thanks, Mike!  You really came through for Sew What? and the Pussycat Dolls!