Commercial Sewing

Commercial Sewing’s relationship with Gerber began when the company purchased its first multi-ply GERBERcutter. 

Since then, the company has added several automated spreading solutions and both single-ply and multi-ply cutters, as well as Gerber’s pattern design, grading, planning and marker making software, AccuMark. 

Over the years, the Connecticut-based company has also acted as a BETA tester for several of Gerber’s cutting solutions, which further strengthened the partnership.

Most recently they beta-tested and upgraded to the new Gerber Atria Digital Cutter. 

With the upgrade, Commercial Sewing saw an increase in material handling which has helped them meet the increased demand they are seeing. With Gerber’s solutions, Commercial Sewing is able to operate a completely automated single-ply and multi-ply workflow.

Since transitioning from a manual to a fully-automated process, Commercial Sewing has seen a significant increase in throughput, material utilization and productivity. 

Today, the company is able to completely connect their supply chain from CAD to the cut room using Gerber’s integrated solutions.

Commercial Sewing is able to easily move seams in Gerber AccuMark to ensure they get the perfect nest. 

The company is then able to quickly send all information directly to the cut room via cut tickets to ensure accurate data transfer for maximum precision. By leveraging Gerber’s end-to-end solution, 

Commercial Sewing achieves 85-90% material utilization, is able to cut up to 50 plies of difficult material and can produce 70-120 covers per day without the need to hire more labor as production grows.

Gerber’s customer support as well as their certified parts and consumables has helped Commercial Sewing stay up and running with very little downtime. 

The company relies on Gerber’s expertise and quality parts to build a truly seamless workflow that will deliver products to their customers as quickly as possible.

“Since implementing Lectra’s automated cutting solutions, we have achieved a remarkable 85-90% material utilization and can now produce 70-120 covers per day. This automation has allowed us to keep pace with a 50-60% rise in demand, even with ongoing labor challenges. We’re confident that Gerber’s technology will continue to be a key partner in our future growth."

Stephan Mazzarelli, Operations Partner 

Commercial Sewing has run into several challenges with demand and labor due to the global pandemic. 

With the water sports industry currently experiencing major demand, the company has received an increased amount of orders. Commercial Sewing is currently challenged with keeping the workforce running at full speed and managing supply chain delays through the demand rush that is happening in the industry. 

If it weren’t for the technology used in their plants, it would only slow them down.

By having a fully-automated workflow, Commercial Sewing was able to stay open throughout the pandemic and expects their orders to be 50-60% higher than last year.

Commercial Sewing continues to work with Lectra to consistently install the latest software and advanced cutting solutions. 

This ensures they can keep up with the latest demand and continue to be a leader in the industry.