Manufacturing - Made in Germany

From the ingredients to the finished product

Once all the ingredients have arrived at our site, most of the further processing and added value services take place in Germany. We work with a portfolio of very good and long-time partners and our own companies, who produce the highest quality fabrics in beautiful colours from our yarns and ultimately our end products. We are in constant dialogue to guarantee the longevity of our products, but also to coordinate our efforts towards greater sustainability at all levels and to develop and try out ideas together.

Sustainable - Made in Germany

As a highly developed industrialised country, Germany has high requirements in terms of social standards, occupational health and safety, environmental protection, etc. Many textile companies relocate their production to less developed countries in order to save costs. We consider these standards to be an important achievement that encourages good management and great efficiency using modern technology. Sure, we can't compete with the low-cost suppliers in the industry. But that is not our aim either.

Many things, such as the energy optimisation of buildings and production facilities, the installation of solar systems, the reduction of water consumption and waste, the optimisation of production processes and logistics and much more have been implemented a long time ago and optimised time and time again - and not just for the sake of sustainability. This is the only way we can finance Made in Germany and sustainability.

The ‘Made in Germany’ seal

The ‘Made in Germany’ seal of quality is controversial because the term is elastic and a statement that is difficult for end consumers to check. There are also no clear legal regulations on how many components of a product must actually come from Germany or which part of the production process must take place in Germany in order for the seal of approval to be used.

Points of reference are:

  • significant production of the goods in Germany
  • decisive share of value added services through assembly in Germany
  • significant finishing of the product in Germany

We are convinced that our products really deserve the ‘Made in Germany’ seal and show below how and where we produce.

Formesse x Welt der Wunder TV

For the Made in Germany TV show, the team of Welt der Wunder TV visited us in October 2020 and filmed a great and vivid report about the production of our fitted sheets.

Have fun watching!
The film is only available in german.

Administration in Löffingen

Formesse's entire administration has been based in the Black Forest since 1947. Here, our customer service team liaises with bed retailers, new products are developed together with our partners, the entire supply chain from the yarn to the end product is coordinated and the high quality is finally checked.

We treat each other with respect and have flat hierarchies. We have a motivated team that supports change and our endeavours for greater sustainability, both on site and in everyday working life.

Facts & Figures

Social sustainability

Occupational safety & occupational medicine

  • Risk assessments
  • Fire protection & first aiders
  • Health protection
  • Occupational health care

 Whistleblower/complaints process

Job bike, direct insurance, healthy lunch offer, new social room

Ecological: Building

Heating:

  • Connection to local heating in Löffingen by the beginning of 2025
  • External wall insulation 2005

Electricity:

  • PV system with 560 m², approx. 120,000 kWh per year
    - of which approx. 20% are for own consumption
    - the rest is fed into the grid
  • Power supply: green electricity from the Löffingen public utility company
  • LED lights: 80%

Ecological: Work

  • Switch to environmentally friendly cleaning agents (2013)
  • Switch to environmentally friendly office utensils (2013)
  • Switch to paperless office since 2016
  • Reduction in paper consumption by 87% since 2019

Ecological: outdoor area

approx. 3,100m² of nature in cooperation with the Southern Black Forest Nature Park

  • Flowering meadows
  • Wild hedges, trees, shrub and insect beds
  • Pond and wetland area
Bufalte

Step 1: Our fabrics are knitted

We knit our cotton yarns and threads exclusively in Germany, and have been doing so in the same knitting rooms for decades. A large number of yarn cones are mounted on a knitting machine at the same time and thousands of knitting needles work together. The cotton yarns or threads are brought together with an ultra-fine elastane thread and knitted into a very durable, long-lasting jersey fabric with a particularly large number of small stitches. Now, with an elastane content of just 3%, our fabrics achieve the desired exceptional elasticity.

Facts & Figures

  • Country of production: 100% Germany (Swabian Alb)
  • Supplier questionnaire for more transparency in progress

2: Finishing & dyeing

In the next step, our fabrics are finished and dyed in Germany. Our partners are continuously investing in state-of-the-art facilities to guarantee the quality of our products, but also to produce in an increasingly sustainable and environmentally friendly way. Textile finishing is a highly complex process that uses a relatively high amount of water and energy, as the fabrics have to be washed, bleached, dyed and dried. Consumption has been reduced as far as possible and the finishing processes optimised for decades due to the high German environmental standards, but also to minimise costs.

Facts & Figures

  • Our finishing (finishing & dyeing) takes place 100% in Germany
  • Supplier questionnaire for more transparency in progress

3: The finishing process

We sew our products for the most part in the nearby Black Forest region or in our own manufacturing plant in neighbouring Alsace. 

The now colourful bale goods are laid out partly manually, partly with machine support, cut by hand with an electric knife and finally sewn, checked, folded and packed by seamstresses. This is physically demanding work, mostly carried out by women. 

Facts & Figures

  • 92% ready-made garments within a radius of 90 km from our site in Löffingen
  • 8% ready-made garments in Poland (as of summer 2024)
  • Supplier questionnaire for more transparency in progress

Facts & Figures

Location: Löffingen, Black Forest // Markolsheim, Alsace

  • Ø employed since: 8 years (2024) // 15 years (2024)
  • min: <1 year / max: 36 years // 1 year / max: 42 years
  • Female/male ratio: 73% / 27% // 88% / 12%
  • Team leadership: 2 women // 1 woman
  • Pay according to job profile (activity, training, affiliation to the company)
  • Nationalities: 7 // 1
  • Sustainability on site: see administration above

We have not relocated even the labour-intensive production stage of sewing to low-wage countries.

4. Product warehouse & dispatch in the Black Forest

Finally, the finished products are all stored at our main site in the Black Forest and are dispatched from here. Here, too, the work is predominantly manual, supported by rolling packing trolleys, forklift trucks, conveyor belts and a lifting device for the heavy parcels. Furthermore, the routes are optimised so that no unnecessary distances have to be covered for this labour-intensive work.

Facts & Figures

  • Ø employed since: 14 years (2024)
  • min: <1 year / max: 44 years
  • Women/men ratio: 75% / 25%
  • Team management: several members
  • Nationalities: 3
  • Formesse Code of Conduct
  • Formesse Key Values

Social sustainability

Occupational safety & occupational medicine:

  • Risk assessments
  • Fire protection & first aiders
  • Health Protection
  • Occupational health care

 Whistleblower/complaints process

Job bike, direct insurance, healthy lunch offer, new social rooms

Ecological: Building

Heating:

  • Connection to local heating in Löffingen (wood chip system)
  • Underfloor heating with hot/cold zones
  • Automatic roller shutters (hot air containment)

Electricity:

  • PV system with 1366 m², approx. 215,000 kWh
    - 100% of which is fed into the grid
  • From mid/end 2024 new PV area with approx. 250 m²
    - of which part of the self-consumption is covered
  • Power supply: green electricity from Löffingen municipal utilities
  • 100% LED lights

Ecological: Work

  • Switch to environmentally friendly cleaning agents (2013)
  • Switch to environmentally friendly office utensils (2013)
  • CO2-neutral shipping via DPD and DHL
  • 97% of outbound logistics by land (2022)

Ecological: outdoor area

approx. 5,800m² of nature in cooperation with the Southern Black Forest Nature Park

  • Flowering meadow
  • Ruderal area
  • Lean meadow (solar area)
  • Percolating paved driveway with wild herbs
  • Wild hedges, trees, shrub and insect beds

Waste avoidance & recycling

We have been working for years on the topic of waste avoidance along the entire supply chain. We use metal transport boxes in rotation from knitting to assembly. Materials that can be used several times are returned to the appropriate production stage. And where possible, we eliminate or reduce packaging.

Unavoidable waste is fed into the recycling system. Waste placed on the market is of course licensed in accordance with the Packaging Act.

Administration & warehouse

Waste separation

Paperless office

Licensing of transport and product packaging

LUCID-No.: DE1312100272847

Knitting

Waste separation

Yarn cones only 50% packed

Bale goods Reusable system Inner tubes

Metal transport boxes according to the rotation principle

Wooden pallets Reusable system

Finishing & Dying

Equipment

Waste separation

  • Bale wrapping reduction depending on colour & quality
  • No bale wrapping or
  • Bale protection through fabric wrapping or
  • Bale wrapping with film

Shipping in metal boxes (rotation principle)

Wooden pallets Reusable system

Sewing

Waste separation

Avoidance of fabric waste

Fabric remnants to recyclers (recycling into felt, cleaning cloths, etc.)

Switch to product packaging made from kraft cardboard

Reusable system Transport cardboard boxes

Wooden pallets Reusable system


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