As environmental standards rise and consumer expectations evolve, the garment and textile industry are under increasing pressure to innovate sustainably. In a recent industry panel hosted by ITMAconnect, an AI-powered online sourcing platform and knowledge hub created for the textile and garment industry. Leading voices from the denim sector shared insights into how technology, creativity, and systemic thinking are reshaping garment finishing. The discussion, rich in innovation and realism, featured panelist Ms Alice Tonello, R&D and Marketing Director, Tonello Srl as well Mr Jacques Mayo, Chief Executive Officer, Compañía Industrial Nuevo Mundo S.A. and moderator Ms Tricia Carey, Circularity Executive and Board Member, Accelerating Circularity, highlighting new possibilities for reducing water, chemical, and energy use in scalable ways.
Tonello, a longstanding leader in garment treatment technologies, is at the forefront of this transformation. Alice opened the session by reflecting on Tonello’s journey since 1981, emphasizing a culture of continual innovation. Tricia, also representing Tonello, outlined their shift from traditional washing machines to integrated solutions like DyeMate, a technology that uses nitrogen to drastically reduce chemical consumption in indigo and garment dyeing. According to her true sustainability becomes scalable only when it is also economically viable.
Jacques added perspective from the manufacturing side, explaining how Rio Alto has transformed legacy systems into vertically integrated, high-efficiency operations. He noted that replacing chemical-intensive processes with digitally controlled, electric alternatives has resulted in lower environmental impact and improved business performance. Both agreed that automation, smart software, and energy-efficient machines form the cornerstone of modern, sustainable denim production.
Water consumption was a major theme. Alice highlighted innovations like nebulisation, which applies chemicals without immersion, drastically reducing water use. She also noted Tonello’s software platform, Metro, which tracks water, energy, and carbon footprint per garment, giving manufacturers clear visibility into their impact. Jacques emphasized the importance of process design: fewer steps, smarter chemicals, and reuse of water across stages have helped his operations cut water use by 30% per kilo over the past five years.
Tricia looked ahead, stating, “In the next five or ten years, garment finishing technology will become more sustainable and digital. The goal is super clear: reduce water and chemical usage—but without limiting creativity.” She noted enzyme-based treatments will remain essential, but the game-changer will be the integration of flexible systems. “Laser, for example, allows us to create effects that are sometimes impossible by hand. And all-in-one systems give us a sophisticated look in a clean and efficient way. The transformation has just begun.”
Jacques and Alice agreed that laser finishing opens a new world of creative possibilities while improving operator safety and efficiency. Alice added that Tonello has even turned attention to less glamorous but impactful stages like drying—reducing energy consumption by 20% with its latest dryer technology. Innovations like DyeMate and their ozone systems are already commercially available and producing strong results for clients like Nuevo Mundo.
As the panel transitioned to Q&A, they addressed challenges unique to fast fashion. Jacques clarified that the real challenge isn’t just speed—it’s adaptability. “A fast fashion customer wants something new every day, but fabric development cycles are long,” he explained. Rio Alto’s solution has been to design fabrics based on modular building blocks. With around 20 warps in production that can accommodate over 100 variations, they maintain both flexibility and efficiency. He also noted a growing tension between reduced order sizes and price expectations, further complicated by the uncertainty of global tariffs and shifting supply chains.
Alice and Tricia responded to questions around the viability of printed denim and digital substitutes. Tricia shared that Tonello has explored digitally printed denim but acknowledged that purists still prefer authentic indigo dyeing. Jacques agreed, stating that while printed denim has its place, especially for fashion-forward or functional applications like uniforms, it hasn’t seen broad commercial success. “True denim aficionados remain loyal to the real thing,” he said.
As moderator Ms Tricia Carey concluded, “Today’s discussion highlighted not only the technical advancements from DyeMate solutions, systems to ozone and enzyme-based processes but also the critical mindset shift that’s required for our industry to embrace the change that needs to happen at scale. Whether it’s addressing water conservation, scaling solutions for small manufacturers or rethinking the economic models behind production and growth, it’s clear that collaboration and system change together are essential.” She emphasized that circularity and systems thinking are no longer optional—they’re critical.
As the denim industry evolves, one thing is clear: the future will be defined by those who innovate with intention, collaborate across the value chain, and embrace sustainability not as a cost—but as an opportunity.
