Cobotics in action: Enova Robotics transforms denim production for Sartex with smart automation

Enova Robotics

Enova Robotics integrates a jeans spraying solution at Sartex

In short

Enova Robotics, a certified Universal Robots integrator based in Tunisia, has developed a jeans spraying solution for the Sartex group, a Tunisian clothing manufacturing company. Integrated into its Ksar Hellal production site in Tunisia, the cobotic cell operates almost autonomously. Sartex has observed significant productivity gains, while improving the working conditions of its employees, in compliance with CSR objectives.

Addressing Operational Risks and Boosting Efficiency

Sartex, a leading Tunisian manufacturer serving global ready-to-wear brands, sought to optimize its jeans spraying station—an essential process for achieving the faded denim look. The manual operation was labor-intensive, repetitive, and posed serious health risks due to prolonged exposure to potassium permanganate, a chemical used for bleaching.

The station’s operator faced multiple challenges:

Health hazards from chemical inhalation, leading to potential respiratory issues. Repetitive strain injuries, particularly musculoskeletal disorders (MSDs) affecting the arms and wrists. Declining precision and quality toward the end of shifts, resulting in increased rejection rates. Space constraints, with a cluttered and inefficient workstation layout. Sartex’s production model includes both large-scale manufacturing and small-batch customization starting from 100 pieces, requiring a solution that could deliver repeatability, flexibility, and safety.

To address these issues, Sartex partnered with Enova Robotics, a certified Universal Robots integrator based in Tunisia. Enova Robotics brought deep expertise in collaborative robotics and safety engineering, developing a cobotic cell capable of automating the potassium permanganate spraying process.

Key challenges tackled during development included:

Ensuring consistent chemical dosing for quality control. Facilitating seamless human-robot collaboration. Achieving high repeatability in spraying patterns. The result: a nearly autonomous cobotic solution that not only improved productivity and product quality but also aligned with Sartex’s Corporate Social Responsibility (CSR) goals by enhancing worker safety and ergonomics.

Enova Robotics

Industry More Industries

Country France

Number of employees 29

Cobot used UR5 and UR10

Main value drivers:

Simplicity and intuitiveness of programming
Almost autonomous operation
Increased productivity
Reduced clutter
Responses to CSR requirements

Tasks solved by collaborative robots:

Safer application of the chemical
Repetition and precision of the gesture
Operator Skills Upgrade

Automation challenges solved:

Adapting the sprayer to the cobot
Reduction of MSDs among operators
Improving the quality of clothing
Reduced chemical exposure
Adaptation of the cobotic solution to the existing infrastructure
Software customization

How they did it

Cost-Effective Automation: Enova Robotics Delivers Scalable Cobotic Solution to Transform Denim Spraying at Sartex

Ten times less expensive than automation solutions previously available on the market, the solution developed by Enova Robotics, based on UR5 and UR10 cobots, was designed to meet the brands' CSR requirements and reduce the workload and risks to which the operator was exposed. Enova Robotics guided Sartex through every step of the process, from application design to integration, all accompanied by training.

Originally, the operator held a sprayer in one hand and applied the product to jeans, one by one, which were hung on a carousel. A physically demanding manual operation that kept him busy all day.

An automated and optimized workstation

The automated workstation consists of an automated carousel in front of which are installed a pair of UR5 or UR10 cobots. These are equipped with an electric gun that will be used to spray potassium permanganate onto the jeans - in the desired locations - that circulate in front of them. The UR10s are intended to bleach larger jeans while the UR5s handle the other series.

The automated spraying process operates in a synchronized manner, with two cobots per carousel. The carousel system, also automated by Enova Robotics, allows the user to move on to another pair of jeans once the spraying process is complete. The process is then repeated on the next pair. Among the constraints, Enova Robotics had to successfully adapt the existing sprayer to work with the cobots. Once this initial challenge was overcome, the challenge was to be able to teach the cobot the gesture so that it could reproduce it with the same precision as the operator and with consistent repeatability.

An ultra-personalized learning and programming solution

Indeed, to ensure that the spraying is carried out correctly according to the desired pattern as well as the jeans model, Enova Robotics has developed specific programming software for Sartex. This solution is controlled via a computer or tablet on site, based on the file sent by the company's internal design office.

With over 20 years of experience, the carousel manager uses a sensor-equipped learning sprayer to reproduce the desired patterns for each series of jeans. The software then digitizes the sprayer's movements and converts them into a program that can be executed by the cobot. It then checks whether the cobot is correctly executing the gesture it has learned. These programs are then saved as a library that is easily accessible to operators on the line's control interface.

All you then have to do is choose the series to print from the library, or scan a QR code on the jeans' label - which corresponds to the series - and the robot will repeat the gesture made by the carousel manager.

Thanks to a toolbox included in the program, the jet's trajectory will be adapted to the size of the jeans. The software solution proposed by Enova Robotics is therefore ultra-personalized.

A successful collaboration between the cobot and the operator

The introduction of spraying cobots has significantly reduced the operator's workload. After the cobots have sprayed, the operator can, depending on the series and production load, perform finishing touches, check the quality of the spraying or, when it has been chosen that the cobot sprays on one side of the jeans, spray on the other side. The adoption of cobots does not lead to job losses but rather to an upgrade in the skills of operators who are repositioned on higher-value tasks.

The high repetitiveness of the initial task is therefore greatly reduced, as are the arduousness and health risks. In addition, since the cobot does not degrade its rate at the end of the shift, the quality of the final result increases.

We developed a custom solution, specifically adapted to Sartex's needs. It allows the carousel manager to use a library of shapes. He can then choose which shape to use depending on the brand. We also added a function to the software that can adjust the jet according to the size of the jeans. Another advantage of our solution: its customization based on the size of the series. All at a controlled cost.

Aymen Soltane, Project Manager at Enova Robotics

Proven Impact: Sartex Achieves Major Productivity Gains and CSR Milestones with Enova Robotics’ Cobotic Solution

The solution perfectly meets the initial objectives of the project, namely a productivity gain thanks to the reduction of the rejection rate (from 30% to 3%). The reduction of arduousness and MSD risks for employees is also achieved, as is the reduction of exposure to chemical products. Thus, an adequate response to the CSR requirements of the brands has been found.

With the unit operating 24 hours a day, 6 days a week, its economic viability was quickly proven. Building on its success with the cobotic spraying solution, the company plans to soon deploy the solution for a brushing task, which is also highly repetitive.

For Sartex, cobotics also represents a potential attractive asset, particularly for a young population that is sometimes reluctant to work in the textile industry.

The carousel leader uses a learning arm to digitize the movement according to the series

The series-specific program is launched via the tablet

The cobots sychronizedly reproduce the movement of the carousel leader

The operator performs finishing or quality control

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