With all critical planning and materials data now connected in a single visual platform, Tunicotex has transformed collaboration, communication and decision-making across its vertically integrated operations.

Headquartered in Soliman, Tunisia, Tunicotex Group, a pioneering force in the global knitwear industry, continues to raise the bar for sustainable fashion with its certified, traceable, and eco-conscious production model. Founded in 1993, Tunicotex has grown from a small Italian-Tunisian venture into one of the world’s leading suppliers of high-quality premium knitwear.

The company operates six knitting workshops, five sewing sections, three ironing and finishing units, a wash plant and an embroidery workshop. Tunicotex produces 16,000 garments daily, 400,000 per month, and 4.8 million annually for global luxury brands such as Hugo Boss, Falconeri, Lacoste, Tommy Hilfiger, Calvin Klein, Moncler, Ralph Lauren, Max Mara, Timberland, Napapijri, North Face and others. Sustainability is central to its ethos, with 95% of raw materials certified to GOTS, GRS, FSC and other globally recognised standards. In 2025, Tunicotex inaugurated its solar power plant, preventing over 650 tons of CO₂ emissions, and the company aims to run entirely on renewable energy by 2026.

Before adopting FastReactPlan, Tunicotex relied on manual Excel-based planning, which caused inconsistencies, delays and fragmented communication across departments. The lack of real-time visibility resulted in unbalanced lines, locked capacities and productivity gaps between machines and workshops. These issues generated unnecessary overtime of 5–10%, high rework levels, short shipments and a reliance on expensive air-freight to meet delayed orders. The business also experienced a 5–10% loss in profit due to inefficiencies, inaccurate forecasts and avoidable errors.

Following this period of operational strain, the business sought a more robust, end-to-end planning solution.

Mr Haithem Bouajila, Managing Director, Tunicotex, said: “Before FastReactPlan, we faced major visibility gaps across our operations. Each department worked from different spreadsheets, which led to inaccurate forecasts, delays and frequent miscommunication. We struggled with locked capacity, planning conflicts and unnecessary overtime, all of which impacted our efficiency, profitability and customer service.”

Tunicotex implemented FastReactPlan across all primary and secondary operations, from knitting and sewing through to washing, printing, embroidery, ironing and packing. By investing in a high-level planning board, four low-level boards and the embellishment planning module, the company established a fully connected planning environment that provides one unified source of truth for all teams.

Since implementation, Tunicotex has realised substantial improvements across its production ecosystem. Planning time has fallen from 40 hours per week to 30; penalty costs have reduced thanks to fewer delays; and cross-departmental collaboration has strengthened through shared real-time data. The improved production visibility allowed Tunicotex to expand its overall capacity by approximately 40% between 2024 and 2025, supporting higher volumes and more diverse orders.

Mr Haithem Bouajila, Managing Director, Tunicotex, explained: “FastReactPlan has transformed the way our teams communicate and plan. We now have accurate capacity visibility, faster decision-making and a much smoother production flow. OTDP has improved significantly, overtime is down and we can confidently take on more orders from our premium customers.”

With greater capacity stability and clearer planning boundaries, Tunicotex also strengthened its continuous improvement culture. Teams now work through a structured Plan–Do–Check–Act methodology, supported by reliable WIP, MRP and FRP reporting. Staff morale has risen as planners and production teams now operate with clearer targets and less firefighting.

Mr Haithem Bouajila, Managing Director, Tunicotex, added: “The visibility provided by FastReactPlan has enabled us to grow our capacity by around 40% in just two years. This level of scalability would not have been possible without the stability and control that the solution gives us.”

Tunicotex selected Coats Digital for its deep expertise in textile manufacturing technology and its reputation for partnership-led transformation.

Mr Haithem Bouajila, Managing Director, Tunicotex, said: “Coats Digital offered not only an advanced planning solution, but also a true partnership approach. Their experts guided us throughout the entire journey and ensured our teams were supported at every stage.”

FastReactPlan is part of Coats Digital’s Manufacturing Solution Suite and is specifically designed to optimise delivery, efficiency and lead times for apparel, textile and footwear manufacturers by integrating capacity, materials and critical path workflows into a single platform.

Liz Bamford, Customer Success Manager, Coats Digital, said: “We are thrilled with the remarkable progress Tunicotex has achieved since adopting FastReactPlan. The solution has enhanced visibility across all operations, improved planning efficiency, increased OTDP, and unlocked additional production capacity. These tangible results demonstrate the power of unified, real-time planning to drive operational excellence and support business growth. We are proud to partner with Tunicotex on its digitization journey and look forward to continuing to help the company achieve even greater efficiency, agility and success in the years ahead.”