Seamless Garments & their increasing scope in Apparel Industry

04 May 2023, Mumbai 

In the global apparel market, seamless clothing quickly becomes a potential growth category as "comfort" becomes the keyword in inner and body-conforming gear.

Citing a quick example of a few garments/categories that can be produced using seamless production techniques such as leggings, sports bras, t-shirts, etc. Apparel exhibitions showcasing seamless garments offer a glimpse into the latest technological advancements and fashion trends in the clothing industry.

What all you need to know

Growth prognosis

According to market predictions, the capacity will double over the coming year. Saying that seamless technology has revolutionized the production world would not be inaccurate. Initial applications of the seamless technology were in the production of undergarments. Such pants are exceptionally comfortable due to the few seams and lack of elastic bands and tags.

The Rise of Smart Technology and Smart Factories

Seamless technology uses specialized circular looms to produce garments that fit the body perfectly without any seams or stitches.

The elimination of the fabric cutting and sewing process optimizes the production process, making seamless production faster and resulting in fewer product failures due to seam failure.

Evolution of technologies; The technology was initially used for manufacturing innerwear due to its comfort, and the demand for seamless products has increased manifold due to a synergy between fashion and functional performance.

It is flexible and allows the making of different structures, and the increased productivity and energy, along with reduced fabric waste, fulfill market needs for shorter timing.

The production time for garments can range from 3-10 minutes from yarn to finish, depending on the complexity of the garment.

Popular choices

Seamless knickers are becoming increasingly popular in the 2020s due to their comfort and smooth appearance under clothing. The manufacturing process for seamless knickers typically involves the use of circular knitting machines that create a continuous tube of fabric without any seams.

Technicalities

First, a design or pattern is created for the knickers using specialized software. The pattern is then transferred to the knitting machine, which uses a series of needles to knit the fabric in a circular motion. The knitting machine can be adjusted to create different stitch patterns and densities, depending on the desired end result.

Intricacies; Once the fabric is knitted, it is cut into the required shape and size using computerized cutting machines that can ensure precision and accuracy. The edges of the fabric are then sealed using specialized equipment to prevent fraying.

The final step in the manufacturing process is adding any necessary finishing touches, such as elastic waistbands or decorative elements. The finished knickers are then inspected for quality control before being packaged and shipped to retailers or customers.

Nuts & bolts; Overall, the manufacturing process for seamless knickers in the 2020s involves a combination of cutting-edge technology and skilled craftsmanship to create comfortable, high-quality undergarments.

The global market scenario

The number of global merchants and businesses aiming to transition a portion of their product offering to seamless is continuously expanding. The benefit of knitting the label information into the fabric also results in tagless clothing, which only increases comfort.

Innovation is the key; Recently, Gap debuted a line of tag-free T-shirts for both men and women at its Banana Republic locations and for men under the Gap brand.

This comes after the introduction of its seamless and tag-free women's T-shirts offered by Gap Body. Barely There, a line of seamless undergarments has also been released by Sara Lee Corp. with a tag-free bra option.

Premium activewear brand Tego had earlier launched a range of T-shirts made from a blend of nylon and polyester. The Summit Seamless range has been developed in the UK and manufactured in Turkey and the seamless body-mapped mesh construction makes for increased breathability and a natural stretch.

The Italian company Cifra designs and produces seamless socks, tights, pantyhose, and seamless garments for intimate apparel, activewear, body shapers, posture garments, and swimwear for leading retailers and brands. Santoni is now a leader in the production of electronic machines for garments without seams and caters to manufacturers of underwear, sportswear, beachwear, medical wear, denim wear, smart textiles, socks, and footwear.

Global market estimate

The global seamless garments market size was USD 19.6 billion in 2020 and is projected to reach USD 26.8 billion by 2025, with a CAGR of 6.4%, driven by rising demand for comfortable and functional clothing and the growing popularity of athleisure wear, according to a report by MarketsandMarkets.

Indian Scenario

Indian apparel brands offer seamless garments for enhanced comfort and fit. Sangam Group had earlier forayed into activewear seamless garments with the launch of its brand C9. Arvind had also earlier forayed Carved in Blue, made with processes including circular knitting for seamless construction, these knitted denims provide a versatile solution for the needs of consumers.

While undergarments are popular, other items like tops, leggings, activewear, shorts, and swimwear are also imported from India. Many retailers already purchase seamless programs from India, including JCPenney, Old Navy, La Sanza, Mother's Work, Benetton, Reebok, Ahlens, Next, Victoria's Secret, and Wisport, with many more exploring their options.

Different strokes in the theater of business; Under the Hanes brand, the corporation makes tag-free knickers for men, women, and kids.

Simply Seamless by Maurice Sasson, an Intertex collection of seamless, vibrant blouses, was a sellout when it debuted in 220 locations, including Macy's, in the spring of 2007. Stepping back due to high sales, fashion brand BCBG Max makes about 40% of its knit tops without seams, up from 10% two years ago.

The volatility in the fashion industry; The idea has gained popularity as it has established a position in the rapidly changing fashion industry for various factors, including synergy between fashion and functional performance.

Adaptability and flexibility; Furthermore, seamless technology is adaptable because it produces structures such as ribs, nets, jacquard, piquet, stripes, and laces in a single step, along with pre-sharpened structures, hidden supports, pockets, collars, and hoods.

Indian Market size estimates

The Indian seamless garments market, valued at around USD 4.4 billion in 2020, is expected to grow at a CAGR of approximately 6.8% between 2021 and 2026, according to a report by IndustryARC.

Transformative or invasive

While meeting the market's demand for shorter lead times, the process also enables the transition from yarn to finished garments to take place in a matter of minutes thanks to the increased productivity and energy, as well as the reduced fabric stock and fabric waste.

"Undergarments take about 3-4 minutes, sleeveless tops take about 5 minutes, and a sleeved garment takes around 8-10 minutes from yarn to finish," said Alok Nayyar of Flying Fashions.

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