The Brazilian industry is experiencing a major transformation. In a rapidly evolving competitive landscape, modernizing production processes is no longer just a trend but an essential step in ensuring efficiency, quality, and market relevance.
In this context, Industry 4.0 emerges. This is a new model that combines technology and strategy to redesign the development, manufacturing, and delivery of products.
With this in mind, you will see how this technological revolution is directly affecting the national industry, especially the textile sector, and why companies that embrace these innovations come out ahead.
Let’s go?
What Is Industry 4.0?
Industry 4.0, also known as the Fourth Industrial Revolution, marks a new era for the sector, introducing a completely innovative approach to how industries operate and produce.
This new phase is marked by the digitalization of production processes, continuing the evolution of earlier industrial revolutions that introduced mechanization, electrification, and automation.
In this new scenario, there are so-called smart factories. They have this name because they connect machines, data, systems, and people through advanced digital technologies, such as the Internet of Things (IoT) and Artificial Intelligence (AI), for example.
Additionally, Industry 4.0 facilitates the continuous exchange of information between physical and virtual systems. This makes production more agile, personalized, and adaptable.
In short, the Fourth Industrial Revolution is fueling the combined use of automation and digital solutions to change traditional production. The primary goal is to enhance efficiency, streamline processes, and minimize waste, costs, and operational failures.
No wonder the Industry 4.0 market is expected to reach US$5.62 billion in Brazil by 2028, according to the Observatório Nacional da Indústria (National Industry Observatory), quoted by Portal da Indústria.
Furthermore, 69% of Brazilian industries have already adopted digital technology, according to another article in Portal da Indústria.
>> Read also: Manufacturing in Industry 4.0: what is the real productive gain?
What are the key technologies of the Fourth Industrial Revolution?
Industry 4.0 is characterized by a set of technologies that enable production processes to become more connected, intelligent, and efficient.
They are as follows:
1. Internet das Coisas (IoT)
The Internet of Things (IoT) connects machines, sensors, and devices into an intelligent network. It enables the collection, transmission, and exchange of data in real-time without human intervention.
2. Artificial Intelligence (AI)
Artificial Intelligence simulates the human ability to learn, reason, and make decisions based on data. It can predict failures, optimize processes, adjust parameters automatically, and solve complex problems.
3. Big Data
Meanwhile, Big Data involves collecting and analyzing large amounts of data produced by industrial processes. It helps identify patterns, predict bottlenecks, and promote ongoing process improvements.
4. Cloud Computing
Cloud Computing ensures remote and secure access to industrial information. It facilitates integration between systems, reduces infrastructure costs, and promotes collaboration between areas and units.
5. Advanced Robotics
Advanced Robotics is a smart solution that performs tasks with precision, speed, and repeatability. It includes collaborative robots that operate alongside humans and adapt quickly to different demands.
6. Additive Manufacturing (3D Printing)
Additive Manufacturing produces parts layer by layer, with agility, economy and customization. Ideal for prototyping and small series.
7. Augmented Reality (AR) and Virtual Reality (VR)
Applied in training, assisted maintenance, and simulations. They facilitate the visualization of processes, increasing safety and operational efficiency.
>> Read also: Maintenance 4.0: What are the implications for industry?
Key benefits of Industry 4.0
The digitization of processes, known as Industry 4.0, offers a range of competitive advantages for companies that adopt 4.0 technologies.
In summary, integrating modern textile machinery and intelligent systems directly leads to strategic and operational benefits, including:
- Greater flexibility, customization, and adaptability to market demands;
- Sustainability through efficient resource use, aligned with environmental and social standards;
- Integration between areas and systems, making processes more agile and synchronized.
In addition to these advantages, according to Portal da Indústria, the main benefits of Industry 4.0 for entrepreneurs are as follows:
- Productivity (72%);
- Higher quality of products or services and reduced operating costs (60%);
- Improvement in the decision-making process (49%);
- Increased worker safety (38%).
>> Read also: Machines for the textile industry: get to know Delta!
Industry 4.0 implementation challenges
Although extremely beneficial to industries, there are some barriers that hinder the assertive implementation of Industry 4.0.
Employees must stay up-to-date on market innovations and, above all, be open to the changes they require.
Furthermore, many factories still operate with outdated machinery and software, which hinders their ability to integrate new technologies effectively. This limitation hinders the digitization of processes and hinders the full and efficient implementation of connectivity.
It’s essential to note that increased data sharing between systems can also lead to greater exposure to cyber risks. In this context, ensuring the security of sensitive information has become paramount.
Industry 4.0 examples in practice
In theory, Industry 4.0 encompasses technologies that integrate equipment, data, and processes. It has been shown to produce tangible, measurable, and significant results in real-world applications. And the cases of Delta Máquinas Têxteis demonstrate this.
Companies of various sizes and segments in the textile sector have already benefited from intelligent automation, standardization, and data integration in their operations. Here are some examples:
- Beckhauser Malhas: reduced production time at the packaging stage by 80%, cut labor in this process by half, and eliminated operational errors, thanks to the EWB700 Automatic Packaging Machine;
- KFK Private Label: By adopting solutions such as the Reviewer, Relaxer, and Sample Washer, the company reduced non-quality costs by 50% and improved speed and predictability in production;
- Objeto Brasil: By automating the shrinkage and torsion testing process with the Sample Washer, it achieved monthly savings of over R$15,000, reducing time, energy, and raw material consumption.
- Havan: started performing laboratory tests in just 14 minutes (previously, it took 3 hours) with the Sample Washer. This initiative has resulted in an 80% reduction in water use and has improved the accuracy of data on fabric performance.
These results demonstrate that Industry 4.0 is more than a futuristic concept. It is already shaping the current state of the textile industry, which seeks greater efficiency, sustainability, and competitiveness in the market.
Prepare your industry for the next steps
The evolution of the textile sector is already a reality! Those who understand the value of Industry 4.0 and anticipate its transformations gain a competitive edge, increased efficiency, and market recognition.
If you are ready to step out of the discourse and put innovation into practice, the next step is simple: deepen your knowledge with technical, reliable, and to-the-point content.
So, download our free eBook and see how textile technology can work for your production!
