Case Study: Malden Mills reduces fabric waste with Datalogic RFID quality control

RFID in the textile industry Malden Mills uses RFID technology for quality control

Malden Mills, the Massachusetts textile company behind Polartec fabrics, needed a better way to track defects in its knit material during production. Bent or broken needles in the 1,700-needle circular-knit machines created runs in the fabric, and the company’s old knot-based inspection method was unreliable, costly, and could damage slitting equipment. Datalogic’s RFID technology was used to improve quality control in this critical stage of production.

Datalogic implemented Escort Memory Systems ES650HT read-only RFID tags, paired and sewn into the fabric around each defect, along with RS427-04 conveyor-style antennas at the drying and splitting station. The antennas detected the tags and signaled the PLC to stop the splitter blade so operators could align the cut with the run, minimizing waste and protecting the machinery. Malden Mills reported that the system reduced wasted material and provided reporting on defects and savings, delivering a more reliable and cost-effective inspection process.

Malden Mills

Shaun Sullivan

Director of Engineering