TEXtalks Interviews BW Converting's Rick Stanford about TexCoat® G4

Under the banner of the industry-leading Baldwin Technology brand, BW Converting manufactures industrial enhancement technology and consumables for the printing, packaging, textile, film extrusion, EV battery, and corrugated industries.

BW Converting offers inline spraying technology that delivers precise fluid and dry powder for a range of applications, including newsprint spray dampening, web remoistening, film extrusion spraying and powdering, and textile finish coating. The systems are designed for efficiency and accuracy, ensuring reduced material waste and faster production times.

The Baldwin TexCoat® G4 is a high-performance textile coating system designed to deliver precise and uniform coating on various fabric types. This system is engineered to improve the overall quality of textiles by providing consistent coating layers, whether for protective finishes, functional coatings or decorative applications. TexCoatG4 is ideal for industries such as fashion, home textiles, and technical fabrics that require precision in coating applications.

Team TEXtalks had a chance to meet and discuss with Rick Stanford, Vice President Global Business Development, Textiles, BW Converting, about the latest technology at IGATEX Pakistan.

TEXtalks: Which innovative and sustainable technologies did BW Converting highlight at IGATEX?

Rick Stanford: At IGATEX, we showcased our Baldwin TexCoatG4 precision spray finishing machine, positioned as a sustainable, high-efficiency alternative to traditional pad applications. Additionally, we presented TexForce, a versatile remoistening system designed for various weaving and knitting processes.

TEXtalks: How do BW Converting’s precision spray application systems set new standards for eco-efficiency and safety?

Rick Stanford: Traditional textile finishing hasn’t evolved much in over a century. Typically, fabrics are fully saturated in a chemical bath, then squeezed and dried using a stenter frame, a method that consumes excessive water and energy. With TexCoat, we’ve revolutionized the process. Instead of soaking the fabric, we spray only the exact amount of chemicals needed, drastically reducing water pickup. Less water means less energy required for evaporation, enabling faster production speeds and significantly improved efficiency. It’s a true paradigm shift in textile finishing.

TEXtalks: What role does the valve spray system play in textile processing?

Rick Stanford: The core of this innovation lies in minimizing water use. When you reduce the moisture content on the fabric, you also reduce the energy needed to evaporate it. This directly translates to lower energy consumption, faster production speeds, reduced costs, and a far smaller carbon footprint. It’s a win-win for both manufacturers and environmentally conscious brands.

TEXtalks: How can BW Converting’s precision spray systems help manufacturers cut water, chemicals, and energy use by up to 50%?

Rick Stanford: In traditional pad-based systems, the chemical add-on rate is often 65–70%. With the Baldwin TexCoat, we reduce that to just 25%. As a result, the fabric is significantly drier entering the stenter, allowing it to move through the machine much faster. For example, one customer doubled their production speed from 60 to 120 meters per minute simply by switching to TexCoat. This means one stenter can now do the job of two, delivering massive cost savings and efficiency gains.

TEXtalks: How much time is typically required for changeover and cleaning with your spray systems?

Rick Stanford: One of the major benefits of the Baldwin TexCoat G4 is that it’s a non-contact system, the fabric never touches the machine. In traditional padding systems, you need to empty a 100 to 150 liter chemical bath during a changeover. TexCoat only uses a compact 3-liter tank, which makes the process much quicker and cleaner. Switching from one formulation (like a softener) to another (such as a water repellent or anti-microbial) takes just 6 minutes, compared to 20 to 25 minutes in traditional systems. This results in less downtime and greater flexibility.

TEXtalks: Where in Pakistan have BW Converting’s systems been successfully implemented?

Rick Stanford: We’re seeing tremendous uptake in Pakistan, with a strong return on investment reported across the board. While our systems are used in a variety of segments, from technical textiles and military fabrics to consumer garments, our biggest success in Pakistan right now is in the bedsheet industry. Baldwin TexCoat G4 has been widely adopted for applying softeners and resins on bed sheeting fabrics, and many customers now operate multiple units, thanks to the system’s proven efficiency and cost-saving benefits.

TEXtalks: What is your perspective on the current U.S. Trade Tariff scenario for 2025?

Rick Stanford: I remain confident that the situation will resolve positively. During my recent visit to SaigonTex in Vietnam, just as the tariffs were being discussed, I saw optimism among factories. Many viewed the changes as potential opportunities, particularly with supply chain shifts benefiting countries like Pakistan. I’m optimistic that the tariff situation will settle, creating more balanced opportunities for global textile markets.

TEXtalks: How has the response been from visitors at IGATEX?

Rick Stanford: This marks our fourth consecutive year exhibiting at IGATEX alongside our trusted partner, Al Ameen. They’ve been instrumental in expanding our presence in Pakistan, maintaining strong relationships with local manufacturers. Each year, we see growing interest in our technologies. At this year’s event, many of our existing customers visited just to share their satisfaction with the Baldwin TexCoat G4, while new visitors came curious about the buzz around our sustainable solutions. There’s a clear shift happening, customers are actively looking to reduce water, chemical use, and carbon footprint, and we’re proud that TexCoat G4 is helping lead that transformation.