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In the ‘Vale das Toalhas’ (Valley of the Towels) in Brazil, 15 family-run manufacturers of towels in the state of Santa Catarina have joined forces. Together, they produce 1,200 tons of terry cloth and 15 million towels and washcloths per month and have created 1,800 direct and indirect jobs in the region.
The success of the Brazilian textile hub is dependent on their joint use of resources such as raw materials and machines and they have relied on Stäubli’s support and state-of-the-art technology for many years.
“Stäubli's support team, who are always on hand, was a key factor in our decision to choose their solutions.
In addition, our second-quality rate used to be around 5 to 6%. Now we are reducing that figure to less than 1%. This boost in quality makes our business more sustainable. We can process a wider range of raw materials and produce much more elaborate designs.”
Brazil has a fast-growing market for textiles and the textile industry is the second largest employer in Brazil's manufacturing industry. However, domestic production is struggling to keep pace with foreign imports. It is essential, therefore, that the members of Vale das Toalhas confront the current challenges of the textile industry: maintaining high quality whilst increasing production, rapid adaptability of developed designs and maximising the lifespan of machines.
By choosing Stäubli machines, the member companies have been able to continuously increase their textile production over time, improve the quality of their textile products and at the same time increase the flexibility of their textile design. The partnership with Stäubli has enabled Vale das Toalhas to compete in a dynamic environment and position itself well for the future.
For over 30 years, family-owned businesses such as Appel Home and LMPeter, used traditional methods of design development which were time-consuming and limited their flexibility. The demand for high-quality workmanship and the minimization of waste were vital concerns.
Thanks to Stäubli’s solutions, Appel Home was able to significantly reduce the scrap rate from 5-6% to less than 1%. "With Stäubli's technology, we are now very flexible and can change designs quickly". continues Appel. Meanwhile, LMPeter has been able to increase production significantly, with its 3-width weaving machines producing almost eleven tons per month.
With its wide range of products and its local range of advice, training and services, Stäubli offers a comprehensive package for the challenges of Vale das Toalhas’ members. There are now more than 200 Stäubli machines in use throughout the Group, ensuring many years of smooth operation at the highest speeds, reduced maintenance and high flexibility for pattern design.
The ‘Valley of the Towels’ has equipped its production facilities with Stäubli solutions for weaving preparation, frame, and Jacquard weaving, harnessing the power of over 200 Stäubli products for its processes:
Vale das Toalhas is poised for further growth and innovation thanks to Stäubli solutions. The Group's collaborative model, combined with the efficiency and quality offered by Stäubli, positions it as a leading force in the Brazilian textile industry. Their commitment to quality, technology and sustainable practices ensures a bright future for the association.
This assessment reflects the high level of satisfaction and trust that the members of Vale das Toalhas have in Stäubli Textile solutions and its complete range of services.
