Getzner Textil AG cuts energy costs and carbon emissions with Cascade System Technology
Getzner Textil AG, a company with over 200 years of history, continues to stay ahead in the textile industry by embracing new ideas and technological advancements. Founded in 1818 as a family business in Bludenz, Austria, Getzner has grown to become a leading manufacturer of fabrics for African fashion, shirts, blouses, corporate wear, and technical textiles. Today, Getzner employs 1,550 people across seven locations and produces 73 million running meters of fabric annually, operating 710 weaving machines.
In a move towards greater efficiency and sustainability, Getzner recently installed a new Prosize staple fiber sizing machine from Karl Mayer in its warp preparation department. This machine, equipped with the Cascade system, promises significant improvements in energy efficiency and reduced operating costs. The results from tests conducted in August 2024 showed impressive outcomes, with steam consumption reduced by up to 3.9% over time, and peak reductions reaching as high as 7%.
The Cascade system works by recirculating part of the steam produced during the drying process in cylinder dryers, allowing the machine to recover and reuse energy efficiently. During the test at Getzner’s Bludenz facility, a drying line with 10 cylinders produced seven weaving beams. The system recycled flash steam from the first six cylinders to support the last four, significantly reducing the need for fresh steam.
The findings confirmed the Cascade system’s efficiency. At full machine load, Cascade contributed 51 kg/h of the required 1,295 kg/h steam through recycling. Even as plant utilization decreased, the system still demonstrated energy savings, with efficiency improved by the temperature difference between the cylinders. The savings potential remains flexible, allowing Getzner to adjust its energy use without sacrificing production quality.
These savings have both financial and environmental benefits. Under standard operating conditions—working three shifts, 5,000 hours per year, with an efficiency rate of 83%—Getzner can save approximately €8,500 annually on steam costs. Furthermore, the system helps reduce the company’s carbon footprint by 59 tons of CO₂e each year.
Cascade also addresses a common issue in boiler houses: wasted thermal energy. Condensate that is too hot for reuse often ends up returning to the system, losing valuable energy in the process. Cascade minimizes this loss without requiring costly additional equipment, offering an effective solution to an ongoing problem.
By prioritizing energy efficiency and sustainability, Getzner Textil is setting an example for the textile industry. This ongoing investment in technology ensures that the company remains at the forefront of fabric production, combining innovation with a commitment to the environment.
