YKK Intends to Unzip Fashion with Cutting-Edge Innovation and Sustainability Overdrive

How does YKK differentiate itself from competitors in the fastening industry?
YKK: The company has developed an integrated production process, from raw materials to final products. This allows for greater control over quality, innovation, and efficiency. We not only manufacture fastening products but also the machinery used to produce them.

YKK is known for its high-quality zippers. What are some recent innovations or advancements in your product line?
YKK: YKK has introduced several innovations aimed at reducing the environmental impact of our products and manufacturing processes:

• AcroPlating Technology: This new metal plating process eliminates the use of harmful substances like cyanide, chromium, and selenium. Compared to conventional electroplating, it reduces greenhouse gas emissions by 96%, water usage by 66%, and power consumption by 69%. It also eliminates toxic waste products and thermal energy use.
• Partnership with Green Theme Technologies: YKK has licensed GTT's EMPEL fabric finishing technology, which allows us to produce DynaPel water repellant zippers without using harmful fluorocarbon chemistries. This water-free and non-toxic solution coats each fibre individually for increased durability and performance.
• Touchlink NFC-Enabled Zipper: This zipper has a Near Field Communication (NFC) chip embedded in the puller, allowing customers to access product information, register warranties, get care instructions, and enable safety features by tapping their smartphone. It also facilitates garment resale, repair, and recycling by providing key information.
• User-Repairable Zipper Parts: This innovation allows users to easily repair broken zippers in the field, reducing the need for garment replacement and lowering the product's carbon footprint over its lifecycle.

How does YKK approach research and development? Can you describe your process for bringing a new product to market? What is the focus on sustainability, transparency, circularity?
YKK: We take a comprehensive approach to research and development. Our process for bringing new products to market involves closely collaborating with customers to understand their specific requirements and challenges to develop innovative solutions. We also have cross-functional teams comprising R&D, marketing, quality, and production experts work together to approach product development from diverse perspectives and overcome challenges. We engage in extensive research and testing to meet stringent quality standards, safety regulations (like OEKO-TEX), and sustainability targets.

Regarding sustainability, as mentioned above, we have set ambitious sustainability goals under our YKK Sustainability Vision 2050 roadmap:

• Reduce greenhouse gas emissions by 50% (Scope 1&2) and 30% (Scope 3) by 2030 from 2018 levels, and achieve carbon neutrality by 2050.
• Switch to 100% sustainable textile materials by 2030.
• Replace all plastic packaging with sustainable alternatives by 2030.
• Increase waste recycling rate to 90% by 2030.
• Develop water-saving production methods and recycle wastewater.
• Eliminate use of hazardous chemicals through new production processes.
• Uphold human rights and ensure fair, safe work environments

What initiatives has YKK undertaken to promote technology along with sustainability within your manufacturing processes, addressing also the environmental impact of its products and operations?
YKK: The company has developed innovative sustainable technologies, eco-friendly products, and comprehensive sustainability goals/initiatives focused on energy, materials, water, chemicals, and human rights to reduce its environmental footprint across the entire product lifecycle.

Sustainable Manufacturing Technology

• ECO-DYE (Waterless Zipper Dyeing Technology): This super critical fluid dyeing technology eliminates water usage in the zipper dyeing process, helping prevent water pollution, and we are working on establishing this technology.
• Eco-friendly Finish (Snap Fastener Finishing Technology): This YKK-original technology for snap fasteners utilises the base colour of materials and does not involve an electrical plating process, reducing water, electricity, and hazardous chemical usage.
• AcroPlating Technology: This plating process eliminates harmful substances like cyanide, chromium, and selenium. It also reduces greenhouse gas emissions by 96%, water usage by 66%, and electricity consumption by 69% compared to conventional methods.

Sustainable Products

• NATULON Zippers: Made from recycled materials like PET bottles and textile wastes through chemical and material recycling processes.
• Organic Cotton Products: YKK uses organically grown cotton to reduce water usage and harmful chemicals on farms.
• Bio-based Zippers: YKK is developing zippers made from plant-based materials as an eco-friendly alternative.

 Environmental Sustainability Initiatives

• YKK Sustainability Vision 2050: Sets targets for reducing greenhouse gas emissions, increasing renewable energy use, sustainable material usage, water management, chemical management, and upholding human rights across operations and supply chain.
• Renewable Energy: Plans to install renewable power sources at facilities, purchase renewable energy, and abolish coal usage by 2025 to reduce emissions.
• Water Management: Aims to reduce water intake, develop water-saving production methods, recycle wastewater, and strictly manage wastewater discharge as per regulations.
• Chemical Management: Following restricted substance lists based on industry standards to reduce and eliminate toxic chemical usage in manufacturing.

How do your products help your clients in their goal towards sustainability, transparency and circularity?
YKK: We offer innovative and durable solutions that reduce environmental impact and enhance social value. For example, YKK's Natulon zipper tape is made from recycled plastic bottles, which saves energy and prevents plastic waste from going to landfills. YKK's GreenRise zipper is made from plant-derived polyester, which reduces the use of fossil fuels and greenhouse gas emissions. 

YKK also provides its clients with information on the environmental performance of its products, such as the Life Cycle Assessment (LCA) and the Environmental Product Declaration (EPD), which measure the carbon footprint, water footprint, and other indicators of each product. Furthermore, YKK supports its clients in achieving circularity by offering repair and reuse services, such as replacing broken sliders or teeth, and by collecting and recycling used zippers.

What trends do you see in the fastening industry, and how is YKK adapting to these trends?
YKK: Some of the trends that we see in the fastening industry are: increasing demand for eco-friendly and biodegradable materials, such as organic cotton, hemp, and bamboo; growing preference for functional and smart fasteners, such as RFID tags, sensors, and biometrics; and rising awareness of social and ethical issues, such as fair trade, labour rights, and animal welfare. 

YKK is adapting to these trends by developing new products and technologies that meet the needs and expectations of its customers and stakeholders. For example, YKK has also introduced Vislon zipper with Revived Top Stop which features a specially designed top stop that allows for easy removal and repair of the slider, contributing to a more sustainable garment lifecycle. 

YKK has also established the YKK Global Criteria of Compliance (YGCC) and creates and operates compliance structures to ensure that each YKK Group company deploys and carries out proper and effective compliance programmes in order to conduct transparent business activities. Each YKK Group company conducts periodic assessment and takes improvement measures in accordance with the YGCC to maintain and reinforce compliance structures.

What challenges does YKK face in maintaining consistent quality across its global operations?
YKK: We face several challenges in maintaining consistent quality across its global operations, including managing different quality standards and regulations in different countries and regions; ensuring the compatibility and interoperability of our products with various machines and materials; training and retaining skilled workers and technicians; and monitoring and controlling the quality of raw materials and components. 

Some of the ways we overcome these challenges is by implementing the YKK Fastening Standards, which are the highest quality standards in the industry; by conducting regular inspections and audits of our production facilities and processes; by providing continuous training and education for our employees; and by sourcing materials from reliable and certified suppliers.

How does YKK manage its supply chain to ensure timely delivery and cost efficiency?
YKK: Our production model is vertically integrated, which means that we oversee every stage of production, from raw materials to finished products. We own our factories, dyeing plants, testing labs, and distribution centres, which helps us to reduce our reliance on external suppliers and intermediaries, and to improve inventory and logistics. YKK also uses our global network of subsidiaries and affiliates, which helps us to meet the local needs and preferences of our customers, and to adapt our production and delivery based on the market conditions and demand changes.

What are YKK's main priorities and goals for the next five to ten years? How does it plan to expand its market presence globally?
YKK: The Fastening Business's Sixth Mid-term Business Policy is designed to achieve sustainable growth in the new normal by adapting to change as a chance and serving society's well-being. We are devoted to providing better products more sustainably, at lower prices, and at a faster speed, enabled by a flat organisational structure that enables quick reaction to the shifting business environment.

The main focus is on improving sustainability with the aim of reaching climate-neutral products and manufacturing processes. By merging sales and development, we seek to improve product planning and development abilities, while also keeping a strict pursuit of cost competitiveness to enhance our core product competitiveness. Digital technologies are being used to ensure hassle-free experiences for both customers and employees, and we are committed to meeting customer turnaround times through careful root cause analysis and countermeasure execution. Last, a high priority is given to health and safety management, with comprehensive disaster and accident prevention measures.

What new markets or industries is YKK looking to enter in the near future?
YKK: We are always looking to expand into industries that require high-quality and innovative fastening solutions, such as the medical and smart clothing sectors.

How has YKK's financial performance been in recent years, and what factors have contributed to this performance?
YKK: The fastening business faced a tough environment in FY2023, as geopolitical issues such as the Russia-Ukraine conflict and Middle East turmoil, along with global economic challenges such as inflation, monetary policy contraction, and a sluggish Chinese property market, affected business sentiment and resulted in high garment stocks. In spite of these obstacles, we gained new clients by improving our delivery efficiency and making strategic price changes.

With so much focus on recycling, how easy or difficult is it to recycle clothing made with YKK products? Are there any research and developments that could speed up the recycling process? For example, there is no need to remove the zipper when recycling。
YKK: Trims are one of the biggest challenges for garment recycling. Just to reiterate, our Natulon recycled zippers are made with ECONYL regenerated nylon. ECONYL nylon, manufactured by Aquafil SpA and supplied in collaboration with ITOCHU Corporation, is made entirely from nylon waste collected all around the world, such as industrial plastic, fabric scraps, old carpets and fishing nets from the aquaculture sector. The material can be continuously recycled without loss of quality.