Industrial Coatings in the Textile Industry
- November 24, 2025
The textile industry is among the largest and most dynamic manufacturing sectors in Europe and worldwide. These production environments are defined by constant mechanical stress, elevated temperatures and persistent friction [1]. From high-end fashion materials and technical fabrics to denim, carpets and hygiene products, manufacturers rely on machinery that must operate reliably under demanding conditions. When machine components are left uncoated, they deteriorate quickly, leading to unplanned stops, increased waste, reduced fabric quality and rising operational costs [2]. Consequently, industrial coatings have become essential for ensuring stable and efficient production, extending the lifetime of textile equipment and safeguarding critical parts [3]. Within this context, the CoBRAIN project contributes to the future of textile manufacturing by developing new coating solutions that combine high performance, environmental responsibility, and digital intelligence.
The Role of Coatings in Textile Processing
Machinery used in spinning, weaving, knitting, dyeing, cutting and finishing are subjected to continuous mechanical and chemical stress. Fibers , abrasive particles and chemical agents interact relentlessly with rollers, guides, nozzles, blades, cylinders and other metallic components. Wear and micro-damage brought on by friction and surface fatigue gradually impair the line’s accuracy and speed. Textile manufacturers are forced to stop production, replace parts, adjust machinery, or discard defective fabric when performance declines Coatings act as protective barriers that maintain stable and clean machine surfaces, limit adhesion, reduce friction and prevent abrasion. Their use supports more consistent fabric quality, higher productivity and fewer operational interruptions. They also contribute to longer equipment lifetimes and lower consumption of energy, water and raw materials [1].
Meanwhile, there is a lot of pressure on the textile sector to reduce its environmental impact. Conventional coating materials frequently contain hazardous elements, and replacing worn machine parts frequently adds to waste, pollution, and resource depletion. Europe’s transition to sustainability requires more intelligent solutions that safeguard machines and comply with more stringent safety and environmental standards [4].
CoBRAIN’s Sustainable Approach to Textile Coatings
CoBRAIN directly addresses this need by developing safe, sustainable, and high-performance coatings for industrial applications, including textile production environments. The goal is not only to extend machine lifetime and reduce maintenance needs, but also to minimise reliance on hazardous substances [5]. This includes evaluating materials from the very beginning of their development and removing those that might compromise ecosystems or human health. CoBRAIN guarantees that coating technologies meet both industrial requirements and present sustainability standards by giving priority to ecologically friendly chemistries and production techniques. Additionally, by better anticipating future restrictions, this strategy helps businesses prevent future production delays or expensive reformulations. Additionally, the project offers a clear path for textile manufacturers looking to modernise their processes while enhancing their sustainability performance by reducing the environmental burden of coating manufacturing and application.
Advanced Coating Technologies and tool for Textile Applications
High-performance coating processes such as High Velocity Oxygen Fuel (HVOF), High Velocity Air Fuel (HVAF), Cold Gas Spray (CGS), and other thermal spray techniques offer substantial advantages for textile machinery. These technologies create dense, strong, and uniform protective layers that resist wear, friction, and corrosion even under demanding operating cycles [6]. Their precision allows machinery to maintain smooth surfaces, a critical factor in protecting sensitive yarns and fabrics during processing. CoBRAIN explores these technologies together with innovative material formulations that respond to the evolving needs of textile manufacturers, from technical textiles to mass-production plants. Researchers no longer need to rely exclusively on time-consuming real-world testing to identify the most effective combinations for improving machine durability and reducing downtime. With the CoBRAIN SDSS tool, it becomes possible to design specialised coatings tailored to specific textile processes, whether for delicate finishing steps or high-speed weaving, simply by entering the required performance criteria.
Thus, the integration of digital intelligence to support industrial decision-making is a key innovation area of CoBRAIN. Instead of reacting to failures, factories will be able to anticipate them, planning maintenance only when truly necessary. This prevents unnecessary shutdowns and reduces waste associated with premature part replacement. Artificial intelligence systems are able to recognise minor patterns that indicate early indications of wear or coating degradation by merging real-time sensor data with past performance trends. This method prolongs the life of vital components and enables maintenance teams to concentrate resources more effectively. Such insights can also direct process modifications and material choices to further improve operational reliability. By maximising energy utilisation and reducing material consumption, the integration of these smart systems will eventually help create a more sustainable production environment [7].
Industrial and Market Impact
Textile manufacturers operate in a highly competitive global market, where speed, cost-efficiency, sustainability, and product quality are key to success. Durable industrial coatings play a crucial role by reducing operating costs, improving uptime, stabilising production quality, and lowering environmental impact through resource savings and longer equipment lifetimes [8].
For Europe, these innovations strengthen industrial resilience by supporting local production with smarter, cleaner, and more durable manufacturing technologies. Advanced coatings also help manufacturers differentiate their products with superior finishes and lower failure rates, directly enhancing consumer satisfaction and brand reputation. By reducing maintenance disruptions and dependency on external service providers, these solutions contribute to long-term economic benefits and supply chain stability. Moreover, extending equipment life and minimising waste aligns with circular economy principles, linking environmental responsibility with operational efficiency. Adoption of these technologies enables European textile industries to meet the growing demand for sustainable production while remaining competitive on a global scale.
Conclusions
CoBRAIN shows that high-performance coatings, sustainable material development, and artificial intelligence are key drivers for the future of textile manufacturing. By creating durable and efficient coatings capable of withstanding intense mechanical and chemical stress, the project addresses fundamental challenges in machine longevity, production stability, and consistent fabric quality.
Artificial intelligence strengthens these advances by enabling predictive maintenance and smarter process optimisation. Through the CoBRAIN SSDS tool, manufacturers will be able to evaluate coating performance, simulate industrial conditions, and select the most suitable coating solutions for specific textile operations. This capability helps prevent unexpected failures, reduces unnecessary maintenance, and improves overall resource efficiency.
At the same time, CoBRAIN promotes sustainable coatings that reduce environmental impact during manufacturing and use. By lowering waste, extending equipment lifetime, and reducing the need for frequent part replacement, the project supports cleaner and more responsible production practices within the textile sector.
By combining innovative coating technologies, targeted material improvements, real industrial testing, and AI-supported decision making tool, CoBRAIN enables textile manufacturers to increase efficiency, reduce operational costs, and respond to the growing demand for environmentally considerate production. Ultimately, the project demonstrates how technological innovation and sustainability can work together to deliver long-term benefits for both industry and the environment.
References
- Hussain A., et al., Mild Steel Tribology for Circular Economy of Textile Industries, Tribology in Industry, 2021, 10.24874/ti.1050.02.21.04
- Kipchumba B. B., et al., Statistical mapping and data collection of critical equipment failures in the weaving section of textile manufacturing, 2024, 10.1002/eng2.12743
- Pandey P. R., et al., Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance, 2023, 10.3390/books978-3-0365-8984-8
- European Commission, EU Strategy for Sustainable and Circular Textiles, 2022, https://environment.ec.europa.eu/strategy/textiles-strategy_en
- Fedrizzi, L., et al., Corrosion and wear behaviour of HVOF cermet coatings, Corrosion Science, 2004, 10.1016/j.electacta.2004.01.043
- Keronite, Surface Coatings for Textile Manufacturing Equipment, 2022, accessed October 2025, https://blog.keronite.com/surface-coatings-for-textile-manufacturing-equipment
- Chen, X., et al., Circular Economy and Sustainability of the Clothing Industry, PMC, 2021 10.1007/s42824-021-00026-2
Gaur, Urjasvita & Kumari, Emarti. (2024). Applications of Thermal Spray Coatings: A Review. Journal of Thermal Spray and Engineering. 4. 106-114. 10.52687/2582-1474/405 10.52687/2582-1474/405
