The global textile ecosystem is facing a pivotal moment of unavoidable change. Manufacturers, from traditional mills to emerging print service providers (PSPs), are grappling with unprecedented pressures: escalating energy costs, growing concerns over water scarcity, stringent compliance requirements and non-negotiable sustainability commitments driven by global brands and consumers. Traditional textile manufacturing, a cornerstone of the industry for generations, is now seen as the source of a fundamental challenge, demanding a revolutionary shift in how fabric is coloured and finished.
The most profound difference between conventional textile printing and the latest digital inkjet technologies is no longer in the final appearance of the garment, but in the ultimate environmental impact. With Kyocera’s FOREARTH technology, the industry has reached a crucial inflection point, positioning sustainability as the core rationale for future textile production while simultaneously delivering vibrant colours, high-definition detail and maintaining desirable fabric softness. The system provides a direct, comprehensive response to the environmental and sustainability challenges that typically define the fashion and textiles industry.
The unsustainable legacy of traditional dyeing
Conventional textile printing and dyeing methods are highly effective at achieving deep colour saturation and economies of scale. However, this efficiency comes at an extremely high cost to the environment.
A typical traditional dye process is a resource-intensive, multi-step marathon, beginning with water and chemical-heavy pre-treatment to scour and clean the fabric. After printing, the dye requires a fixation stage using steam or high heat, followed by the most water-intensive step: washing-off, where the fabric is thoroughly rinsed to remove excess dye and chemicals.
Industry estimates are sobering: conventional wet processing typically consumes between 100 and 200 litres of water per kilogram of finished fabric. This significant water usage, combined with the resultant wastewater discharge and heat-intensive processes, makes conventional dye methods major contributors to water pollution and high CO2 emissions.
Furthermore, these large-batch setups necessitate minimum order quantities, creating a rigidity that actively struggles to align with modern on-demand market demands.
The “Triple-Free” philosophy: The blueprint for textile transformation
FOREARTH is not just an incremental improvement on digital printing; it is a holistic solution built to simplify and de-risk the entire textile production chain. Heidie-Mari Middel, Production Print Team Lead at Kyocera Document Solutions South Africa, encapsulates this innovative approach.
‘What I find exciting and what I believe sets this device apart is it’s direct response to current environmental and sustainability challenges that we typically find in the fashion and textiles industry. I describe FOREARTH as being our “Triple-Free” philosophy, which highlights three core innovations that set the system apart: Water-Free, Creative-Free and Location-Free,’ she says.
This philosophy tackles the three main challenges of traditional textile production head-on.
Water-Free: Eliminating the most critical constraint
The Water-Free concept reflects FOREARTH’s ability to drastically reduce water usage compared to traditional analogue dyeing. This paradigm shift is achieved by utilising Kyocera’s proprietary pigment ink system, which eliminates the most water-hungry stages of steaming and the extensive washing-off process.
Middel demonstrate the magnitude of this reduction: ‘A traditional process uses an estimated 153 litres of water per 1 kg (L/kg) of fabric, whereas FOREARTH reduces consumption to a mere 0.02 L/kg of fabric. This near-total elimination of water consumption is made possible through our intelligent, closed-loop water recycling system specifically designed for cleaning the conveyor belt.’
Unlike conventional printing, which relies heavily on water for pre-treatment, steaming, washing and waste flushing, FOREARTH uses water only in a controlled cleaning spray to prevent ink build-up on the belt surface. This water is captured in an internal tank, filtered through multiple stages to remove fibres, lint, pigment residue and other solids, which is then recirculated back into the cleaning mechanism.
‘Because the same water is reused continuously, fresh water input is minimal and wastewater output is nearly zero. This controlled, closed-loop approach ensures consistent print quality by keeping the belt clean, stable and free from ink contamination throughout the production run,’ she adds.
Creative-Free: Unlimited design and material flexibility
The Creative-Free concept focuses on design freedom and material versatility. Traditional dyeing demands different dyes and chemicals for different fabric types, forcing manufacturers to invest in and maintain multiple chemistries for silk, cotton or polyester. FOREARTH resolves this inefficiency.
‘The system uses our proprietary pigment-based ink together with optimised pre-treatment and finishing agents. This single-system chemistry enables FOREARTH to print on a wide range of textiles - including cotton, polyester, silk, nylon and blended materials - without requiring separate dye systems,’ Middel explains. ‘This versatility also extends to handling delicate and heat-sensitive media like acetate. While, as with all pigment-based digital textile printing technologies, there are material constraints such as very irregular surfaces or heavily coated fabrics, the system is highly adaptable.’
Kyocera demonstrates this commitment to pushing boundaries by printing on unique, newly created
and sustainable substrates. At ITMA 2023, FOREARTH successfully printed on orange fibre fabric, a regenerated-cellulose, citrus-based textile. This physically demonstrated the system’s capability to print on new, cellulose-based sustainable fabrics and to preserve the fabric’s hand and drape while producing high-definition prints.
Location-Free: Decentralised and on-demand production
The Location-Free concept emphasises production freedom and supply chain agility. Because FOREARTH does not rely on large amounts of water or extensive pre- and post-treatment facilities that require specialised plumbing and infrastructure, it can be installed virtually anywhere, even outside traditional, high-infrastructure textile hubs.
‘This unique freedom supports on-demand and small-batch production closer to the point of sale, known as localised production. By facilitating this geographic flexibility, FOREARTH drastically helps to reduce overproduction, eliminates the need for excess inventory, lowers significant logistics costs and slashes lead times. PSPs can transition away from rigid, large-batch setups to an efficient, sample-print-mode workflow that allows printing on fabric sizes as small as A4,’ she stressed.
Colour science, softness and compliance
The vibrancy and longevity of FOREARTH’s prints are driven by Kyocera’s own patented water-based pigment inks. These environmentally friendly inks deliver the high density and brilliance that characterise the device’s exceptional output, supporting up to eight colours plus special colours (CMYK plus up to four additional hues). This expanded gamut enables richer, more saturated colours than a standard CMYK pigment setup, ensuring unparalleled colour accuracy.
‘This enhanced colour accuracy and perceived vibrancy are further refined through the Kyocera-developed “Picfy” pigment ink and the KIPS (Kyocera Integrated Printing System) printhead,’ Middel elaborates. ‘The KIPS precisely controls circulation, temperature and viscosity, ensuring stable drop and dot placement. Sharper dots naturally translate to more vivid optical saturation on the final textile.’
Crucially, the pursuit of vibrant colour is not achieved at the expense of the fabric’s original quality. FOREARTH uses proprietary pre-treatment and finishing agents designed for a continuous, circulating cycle alongside the pigment ink. This maximises each fabric’s performance while maintaining exceptional softness, even on delicate materials like silk and chiffon. Unlike the heavy binder films used in older pigment processes, this chemistry leaves a uniquely soft finish. Furthermore, the simplicity of the digital process itself is beneficial through the elimination of multiple wet-steaming and washing steps common in conventional dyeing processes.
‘Risk and compliance are also built into the core chemistry. All Kyocera pigment inks, pre-treatment and finishing agents carry the prestigious ECO PASSPORT certification. This international standard guarantees the components meet stringent safety requirements for hazardous substances, providing indispensable assurance for accessing global supply chains and meeting the environmental mandates of corporate clients,’ Middel highlights.
Operational freedom and future-proof business value
The financial and operational impact of adopting FOREARTH is seen not only in cost savings but in competitive positioning. The system is an excellent fit for PSPs who prioritise sustainability, efficiency and versatility.
Middel explains: ‘For eco-focused manufacturers, the system’s near-waterless process directly supports modern environmental standards and brand expectations, turning an environmental constraint into a competitive edge. This directly translates to lower operational costs due to significantly decreased water and energy consumption, offering a more predictable and stable cost base, particularly in regions where energy prices are rising and water stress is intensifying.’
The adoption of digital textile printing with FOREARTH is a natural extension of a PSPs core expertise, bringing high-speed digital workflows, precise colour management and fast turnaround times into the business. Kyocera’s commitment, rooted in its management rationale to contribute to the advancement of society and humankind, is embodied in the FOREARTH platform, giving textile printing companies a powerful, commercially viable way to sidestep the environmental and economic burden of traditional methods.
As energy costs continue to climb, water stress intensifies globally and brands universally seek greener, more compliant suppliers, the advantage of a water-free system will only become more profound. The future belongs to clean production – and this device is the essential foundation for that new era.
‘FOREARTH empowers businesses to expand their creativity and generate new value while contributing to a better future. It is the necessary answer to the environmental pressures of today and the essential foundation for a profitable, responsible textile industry of tomorrow,’ Middel concludes.