Gulle Entegre Tekstil exploits advantages of machines from Thies
Following a significant investment in new machines from Germany's Thies, Gülle Entegre Tekstil now has a daily production capacity of 40 t of dyed yarn and the same for dyed knitted fabric.
The company is looking to exploit the considerable advantages of its accumulated know-how and Turkish location, to build on its reputation as a leading exporter of yarns and fabrics, according to Ismet Gülle, one of four brothers now at the helm of the company which was founded by their father in 1970.
With its headquarters in Avcilar, Istanbul, the company's manufacturing operation are located in Çorlu. Çorlu is situated some 70 km west of Istanbul and has boomed over the past decade, its population having risen over the past 20 years from barely 20,000 to 250,000 people, largely as a consequence of the new textile mills which have been built in the region, and now number approximately 350 in total.
Gülle's operations consist of integrated knitting and yarn manufacturing, yarn and fabric dyeing and printing. It also has its own energy plant and employs 750 people.
“Our regular production is of cotton and viscose and their blends,” said Mr Gülle, “but we have also developed special yarns employing fibres such as Trevira and Outlast, as well as other small lots of wool and silk.”
The Thies installation has been put in place over the past three years and consists of both yarn and piece dyeing. In total, the state-of-the-art plant houses 16 vertical ecobloc-x machines, two RIII high pressure dryers, eight rotoMaster units and four mini-soft machines. These machines vary in capacity from an hourly 25kg up to 600kg.
The versatile ecobloc-x machines can handle packages, warp beams or loose material providing not only the highest standard treatment of the material but also allowing economical process control.
Reproducible quality, shorter production times and cost reduction by energy savings are the key benefits of the RIII pressure dryers, which are engineered to avoid over-drying, yellowing or migration.
The rotoMaster has a reputation world-wide for its operational reliability and versatility. By the special piling and gentle movement of the fabric, the rotating drum provides an optimal product.
The Thies mini-soft are positioned next to the company's laboratory for both testing and small-lot production. Shading is tested and corrected on these units before going into regular production, since the results can be transferred all of the bigger dyeing machines to ensure best quality and product in advance.
The Gülle dyeing operations are also equipped with a centralised automated system for dispensing the chemicals, dyestuffs, salt and soda required in production.
“Our strategy in investing in this Thies installation was primarily to reduce the costs related to labour and energy, as well as using less dyestuffs,” said Mr Gülle. “We have now reached this position. The textile sector is not easy at the moment and quality is the only answer.