The Turkish company Zirve Tekstil has created a production setup that delivers outstanding yarn quality, recognized worldwide, by combining the best technologies from Trützschler, Toyota and Murata. The mill produces 18.5 tons of premium combed ring yarn daily in counts of Ne 20, 24, and 30, primarily for knitting applications. Although the focus lies on utilizing locally grown cotton, which typically comes with greater variability in fiber properties, the mill successfully produces yarns that are in high demand both in demanding local markets and in international export markets.
For the best quality: one brand or the best combination?
“We knew a one-brand setup might be easier,” says Erhan Tenekeci, the company‘s General Manager. “But our goal was to stay competitive, which meant choosing the best in every category, Trützschler for fiber and spinning preparation, Toyota for roving and ring spinning frames and Murata for winding.”
The first step: spinning preparation
The Trützschler bale opener BO-P gently opens the fibers and ensures the best possible blending from the start. The Pre-Cleaner CL-X stands out with its outstanding cleaning efficiency while significantly reducing the loss of good fibers. All in all, Trützschler’s blow room solutions lay the foundation for consistent quality and economy in yarn manufacture.
The intelligent card TC 19i, equipped with SUPERTIP wires from Trützschler Card Clothing, further contributes to unmatched sliver quality through the automatic gap optimizer T-GO, which is only available from Trützschler. The card also features WASTECONTROL, which prevents any unnecessary fiber loss. In the combing stage, the TCO 21 Comber stands out with its dual-drive technology and automatic piecing optimization, delivering uniform quality across all eight heads – even at high speeds. It also enables top quality at low noil levels. Together with the high performance draw frames TD 9T and TD 10, these Trützschler spinning preparation machines form a tightly integrated system that transforms raw cotton into a perfectly prepared sliver, thus creating the basis for further processing.
The second step: roving and ring spinning
In the roving stage, four Toyota FL200 Roving Frames ensure high-quality rovings even at low twist levels – a key factor for downstream performance. Twelve Toyota RX300 Ring Spinning Frames provide exceptional stability and precise spinning geometry. As Erhan Tenekeci, General Manager of Zirve Tekstil, explains: “Despite being limited to 1,824 spindles, Toyota’s compact ring machines produce more and higher-quality yarn than even the longest machines of competitors. Their performance, combined with low maintenance and high adaptability, gives us a clear edge.”
The third step: winding
The final step is handled by the Muratec FPRO EX Automatic Winder, seamlessly connected via Coner Link. This setup ensures smooth yarn transfer, minimal contamination, and consistently high winding quality – completing a process chain where every detail is aligned for excellence.
In addition, Pinter, the provider of the OptiFil system, has recognized the mill for achieving the highest efficiency within its Turkish benchmarking network, with the lowest yarn breakage rates– a clear indicator of the outstanding fiber preparation.