Innovation meets environment

For us, environmental protection is more than just a catchphrase

The headquarters of Getzner Textil are located in one of the most beautiful parts of the world, which is why the environment lies very close to our hearts and why, when it comes to product development, it receives just as much attention as customer benefits. Our team is committed to improving the environmental performance of all our company locations. Not content with just making an active contribution towards environmental protection, sustainability is ingrained in our company culture.

We produce innovative textiles of the highest quality

Getzner Textil AG was founded in 1818 as a family-owned company in Bludenz, Austria. At present, the company is one of the world’s leading manufacturers of clothing damasks, fashion fabrics as well as technical textiles and employs more than 1,600 people.

We manufacture clothing damasks, fashion fabrics for shirts and blouses, and technical textiles of the highest quality. In addition to the weaving mill and preparation facilities, Bludenz is home to the finishing operation, including pretreatment, yarn dyeing, piece dyeing and finishing. It is also the location of our workshops, the technical department, warehousing and dispatch, and the admini­stration department.

Environmental protection is anintegral part of the production process.

We take environmental protection very seriously. Ecology and sustainability are core elements of our corporate philosophy. Protection of the environment and our natural resources take the highest priority and are part and parcel of our business objectives.

The pretreatment facilities (bleaching, washing and mercerisation) and the equipment for the dyeing of fibres and textiles come under what is known as the IPPC Directive (Integrated Pollution Prevention and Control), which requires an integrated plant licence that covers all the environmental media – air, water, waste, soil and energy. Although a traditional ­company, Getzner Textil operates state-of-the-art machi­nery. Water consumption is monitored, as is the recycling of waste water, and any waste heat is re-used for heating purposes.

Yarn dyeing plant
The yarn dyeing plant is highly automated. All the equipment is fitted with heat recovery systems. Waste water from the entire finishing process is neutralised using flue gas from the steam boiler. The yarn is pretreated, dyed and dried in the yarn dyeing plant.

Weaving mill and preparation facilities
The weaving mill and preparation facilities are operated at the highest levels of energy efficiency. Cutting-edge weaving machines and a wide range of technologies are used.

In 2001, a district heating network was constructed that enables the recovered process heat from the compressed air station and steam boiler to be used in the surrounding public buildings. This has been a huge success. The total annual heat input into the network is roughly 8.2 GWh, of which the company uses around 3.7 GWh each year.

The weaving machines are installed on flexible mountings and fitted with state-of-the-art shedding machines in order to reduce vibration immissions to below the perceptible threshold, even for residents living directly next to the weaving mill. In the warping department, ma­chines are used to wind the individual yarns onto a warp beam, while in the sizing department, each warp thread is covered with size to protect it during further handling. Today, we use the latest technology in the form of a new sizing trough. This allows us to reduce the residual fluids requiring disposal by up to 90 % per batch. The weaving mill also houses the threading section and raw material inspection department.

Raw material warehouse
The raw materials are stored in a fully automated, high-bay warehouse in which robots sort the fabrics for the subsequent finishing processes.

Piece dyeing plant
New machinery has been installed in the piece dyeing plant, and further investment has been made in a waste water management system.

The continuous washing processes in the water heat recovery units have resulted in a saving of around 5.2 GWh per year. The energy

saving from the discontinuous processes is approx. 3.7 GWh per year. The piece dyeing plant contains the piece cleaning machines, which use brushes to remove any heavy soiling from the fabric. It also houses the singeing machines, which burn off any protruding fibres, the open-width washing machine and a hot flue for dyeing the fabrics.

During mercerisation, the fabrics are treated with a sodium hydroxide solution that improves colourability, increases stability and gives the fabric a silken sheen. Getzner Textil has been using a lye recovery system since the early 1970s; the system was completely reconditioned in 2004. It reduces the fresh lye requirement and optimises energy usage. Thanks to heat recovery, the lye recovery system saves approx. 1.6 GWh of energy every year. The waste heat is likewise used for heating and ventilation systems.

Finishing
We have made considerable investments within the finishing department in waste air puri­fi­cation and exhaust air heat recovery. The extremely high degree of automation ensures that the pro­cesses are very efficient.
A wide range of detergent solutions are applied to the stentering frame, where the widths are adjusted and secured in place. A biofilter system is used for cleaning the exhaust air of the stentering frame. The Sanfor is then used with dry heat to shrink the fabric in the warp direction to stabilise the shrinkage.

All the process and potable water is supplied from two company-owned well systems.

Folding, final inspection and dispatch
Once the fabric has passed through each process, it ends up in the folding, final inspection and dispatch department. It is also manually inspected on inspection tables. The fabric is then either rolled or doubled according to customer requirements.

Ensuring that all the various processes are completed on time is an extremely complex logistical operation.

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