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Technology

BW Converting
TexCoat® G4 Precision Spray Finishing Technology

BW Converting’s Baldwin TexCoat® G4 Precision Spray Finishing Technology reduces processing demand in textile finishing by applying chemistry directly and accurately onto the fabric surface. This non-contact system can be integrated into any stenter or relax dryer, significantly lowering water use compared to traditional padding methods. With less water to evaporate, less energy is required - cutting both costs and emissions by up to 50% while increasing line speeds. In addition, the contact-free application eliminates bath contamination and allows seamless formulation changes without downtime, regardless of fabric or color.

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Solution tier focus

TexCoat® G4 Precision Spray Finishing Technology focuses on Tier 2.
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Tier 4
Raw material extraction
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Tier 3
Raw material processing
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Tier 2
Material production
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Tier 1
Finished product assembly

Solution maturity level

Pre-seed

Definition:
Solutions that are at a concept level and in the process of evaluating and establishing their impact potential.

Pilot

Definition:
Solutions that are in the process of testing their solution in order to demonstrate a proof of concept.

Model

Definition:
Solutions that are working towards de-risking and reducing known barriers to scale.

Scale

Definition:
Solutions that are commercially viable with a proven go-to-market strategy.
Goal:
Our goal is to scale geographically and take the technology into other departments within the textile supply chain.
Scale
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Current Level
Pre-seed
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Pilot
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Model
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Scale DEFINITION
Solutions that are commercially viable with a proven go-to-market strategy.
swirls graphic blueLEARN MORE ABOUT OUR MATURITY LEVELS
Current Level
Goal Of This Scale Solution
Our goal is to scale geographically and take the technology into other departments within the textile supply chain.
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Pre-seed DEFINITION
Solutions that are at a concept level and in the process of evaluating and establishing their impact potential.
LEARN MORE ABOUT OUR MATURITY LEVELS
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Pilot DEFINITION
Solutions that are in the process of testing their solution in order to demonstrate a proof of concept.
LEARN MORE ABOUT OUR MATURITY LEVELS
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Model DEFINITION
Solutions that are working towards de-risking and reducing known barriers to scale.
LEARN MORE ABOUT OUR MATURITY LEVELS

Location Availability

The solution is available globally.
19
Available regions
83
Sites
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Actual Solution impact

Impact is calculated over the duration of the solution.
What are the different saving types?
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GHG savings
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0.15
kgCO2e
Average actual savings per kg of production
44% Average
Energy savings
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1.91
MJ
Average actual savings per kg of production
44% Average
Water savings
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0.00042
M3
Average actual savings per site/year
68% Average

Financial breakdown

An upfront capital expenditure is needed to achieve savings in chemicals, energy, water, and increased productivity. Capital investment is dependent on the number of lines to be equipped.
Site Investment
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Implementation cost
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18-24
Payback period
Average payback in months
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The average length of time required for an investment by a site to recover it's initial outlay in terms of profits or savings.
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1
tCO₂e =
$43.89
$67 industry average
Payback period
Average actual total investment cost per tCO₂e reduction
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The cost per tonne of CO₂e reduced as a result of the solution(s) over the useful life of each project, including brand and site program contributions, as well as all implementation costs.

Invested COST PER tCO₂e

DISCLAIMER: These are average projected values, average cost and impact ratios will depend on site specific implementation.
What are the different saving types?
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Implementation Plan

Initial meeting with customer to discuss their current process and how our technology can be integrated and projected ROI. Quotation is submitted to the customer. Order is placed. Pre installation meeting(s) held to define the responsibilities of the customer and supplier to prepare and implement the technology. Installation, commissioning, training and the process implementation.
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12months
Projected project length
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Implementation milestones

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1
Commissioning
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2
Training
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3
Quality checks to ensure technology is achieving and/or exceeding existing process
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4
Measure speed and productivity increases
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5
Measure chemical and water savings
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Measure energy savings


Case Study

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1 Region
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1 Site
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1 month

Impact

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GHG saved
97,431
tCO2e
Energy saved
195,703
GJ
Water saved
223,250
m3

The Challenge

Bluwin conducted a study of BW Converting’s technology on an existing facility using the solution. Bluwin recorded the impact of the Baldwin TexCoat G4 precision spray technology for controlled and targeted application of water and chemicals during textile finishing processes. The system applies liquids to one or both sides of the fabric using a non-contact spray mechanism, ensuring optimal coverage while minimizing water and chemical use. Compared to standard Foulard technology, the BW Converting system reduced total power consumption by 49% and thermic power usage by 43% per kilogram of production. Production throughput increased by 27%, with processing speeds rising from 14.2 m/min to 18 m/min, resulting in improved energy efficiency and reduced GHG emissions in textile operations.
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Solution providers

BW Converting

Under the Baldwin Technology brand, BW Converting manufactures industrial enhancement technology for the printing, packaging, textile, film extrusion, advanced battery, nonwovens, and corrugated industries, as well as other high-performance industrial applications

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Interested in this solution?

Get in touch to learn more about how to implement this solution
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