Cutting Through Challenges: From Lost Cargo to Excellence at Texprocess Americas 2025

Blog Post

In a candid conversation, John Hollo, CEO of Pathfinder, reflects on the triumphs and trials of showcasing at Texprocess Americas 2025, revealing the ingenuity behind their flagship X-Calibre cutter, the future of cutting, and why Pathfinder is at the forefront of cutting technology.

John, Pathfinder made quite the impression at Texprocess Americas this year. But it wasn’t exactly smooth sailing in the lead-up, was it?

John Hollo: That’s putting it lightly. We shipped a 40-foot container with all our booth equipment, including machines and marketing materials, well in advance. But two weeks before the exhibition, we were notified it might not arrive on time. Turns out it got routed through the Panama Canal—twice. We had to scramble.

We ended up air-freighting our development R&D machine—the X-Calibre—which was never intended to leave Australia. It was an internal development unit, not a production model. We also pulled equipment from our Indianapolis office, and trucked the X-Calibre non-stop from LA airport to Atlanta using a team of drivers. The truck didn’t stop for anything but fuel. It was intense—fortunately it arrived one day before setup.

That’s some dedication. What exactly did Pathfinder showcase at the event?

John Hollo: We set up two full cutting room demos, unfortunately without a single-ply cutter due to the shipping issue. The centerpiece was the X-Calibre—a glimpse into the future of intelligent, automated fabric cutting. The machine that understands the fabric it cuts. Even though it’s still in development, it performed flawlessly throughout the show.

Alongside that, we had the EasyLoader conveyor table synchronized with the cutter, the FabricPro spreading machine, and the M-Series with the EasyFeeder. On the M-Series, we demonstrated high-speed adaptive pattern matching—something that created a lot of interest. We also had a leather nesting station to round out the booth.

One highlight was a fun demo: a stuffed kangaroo operating the machine. It got attention and smiles. It helped emphasize how intuitive and easy our systems are to operate.

Was there any feedback that stood out to you?

John Hollo: Definitely. One of our newest team members—who had spent 35 years in our industry—was surprised by the level of advancement in our technology. And I don’t use that word lightly. He was surprised by everything—from how we cut 60 layers of denim without a buffer, to the simplicity and intelligence of our spreading system.

He was particularly surprised at our adaptive pattern matching. While competitors rely on complex lighting and cameras, we use a simple camera—no lights, no fuss. Yet we achieve dynamic, real-time recognition of patterns with exceptional accuracy.

Let’s talk about X-Calibre. You mentioned it solves some fundamental problems in the cutting process. What makes it so different?

John Hollo: The biggest issue in the industry is optimisation. Usually, when a machine is installed, it’s calibrated manually by an application specialist based on their experience. That setup is subjective and varies from person to person. Furthermore, over time, operators change, new materials are introduced, and optimisation degrades. It's not unusual to see machines running at 50% of their potential because no one knows how to optimise parameters.

X-Calibre changes that. This machine takes over the complex task of optimisation. It analyses the fabric as it cuts and adjusts key parameters in real time to ensure consistent performance. At the exhibition, we demonstrated this by cutting 60 layers of denim with zero buffer—completely managed by the machine’s internal logic. It was a moment that demanded trust—and the machine delivered perfectly.

That’s a powerful shift. Could you compare it to how other technologies have evolved?

John Hollo: Imagine being a driver 50 years ago. You needed to understand the mechanical details of your car—how the carburettor worked, how to change gears, when to use the choke, etc. Today, you just drive. X-Calibre brings that same leap to automated cutting. You don’t need to be an expert anymore. You just load your fabric and go.

What’s next for customers who invest in the X-Calibre today?

John Hollo: They’re buying into a roadmap. We have a clear blueprint of features we’re enhancing. 

Reliability & low maintenance is a key factor in our customers decision to invest in Pathfinder. X-Calibre builds on Pathfinder’s exceptional reputation in delivering the highest level of profitability while maintaining lowest operational costs. 

The reciprocating knife path represents most of the cutting machine's movements. X-Calibre has very few wearing parts in its knife path. That eliminates a huge source of wear and maintenance. The few components that do wear are long-lasting, low-cost, and easy for operators to replace themselves. Even lubrication is automated.

It’s a revolution not just in productivity, but in ownership. Less maintenance, lower costs, and fewer headaches.

One last question—how did you feel at the end of it all?

John Hollo: Relieved. It was three intense days after an even more intense build-up. But everything worked. The R&D X-Calibre, which wasn’t even meant to be there, performed perfectly. The team pulled together under pressure. And the interest we received proved we’re pushing boundaries.

If you had to sum it up in one message—for the industry, for your customers—what does Pathfinder stand for today?

John Hollo: Pathfinder isn’t just keeping up—we’re defining the future. Our technology is about making complexity invisible. We simplify the hard parts. And we’re doing it better, faster, and smarter than anyone else. That’s what Texprocess Americas 2025 proved.

Click here to learn more about Texprocess Americas.

This interview was originally published by SPESA member Pathfinder June 4, 2025.

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