Trützschler, Toyota And Murata Power Zirve Tekstil’s Yarn Excellence

In today’s textile industry, excellence is not achieved by chance, it is the result of deliberate decisions, technical expertise and the courage to move beyond conventional approaches. Turkish company Zirve Tekstil has done exactly that. By combining leading technologies from Trützschler, Toyota and Murata, the company has created a production setup that delivers outstanding yarn quality recognized worldwide.

“We knew a single-brand setup might be easier,” says Erhan Tenekeci, General Manager of Zirve Tekstil. “But our goal was to remain competitive, which meant selecting the best in every category, Trützschler for fibre and spinning preparation, Toyota for roving and ring spinning frames, and Murata for winding.”

The intelligent Trützschler card TC 19i, equipped with SUPERTIP wires from Trützschler Card Clothing, ensures that every fiber is perfectly aligned, maximizing both quality and efficiency.

Excellence in yarn manufacturing begins with spinning preparation. The Trützschler BO-P bale opener gently opens fibres and ensures optimal blending from the outset. The CL-X Pre-Cleaner outperforms competitors with outstanding cleaning efficiency while significantly reducing the loss of good fibres. Overall, Trützschler’s blow room solutions lay the foundation for consistent quality and cost-efficient yarn production.

The intelligent TC 19i card, equipped with SUPERTIP wires from Trützschler Card Clothing, further enhances sliver quality through the automatic gap optimizer T-GO available exclusively from Trützschler. The card also features WASTECONTROL, preventing unnecessary fibre loss.

In the combing stage, the TCO 21 comber stands out with dual-drive technology and automatic piecing optimization, delivering uniform quality across all eight heads, even at high speeds, while achieving top quality at low noil levels. Together with the high-performance TD 9T and TD 10 draw frames, these spinning preparation machines form a tightly integrated system that transforms raw cotton into perfectly prepared sliver, creating the ideal basis for subsequent processing.

Trützschler’s spinning preparation machinery transform raw cotton into a perfectly prepared sliver.

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 Tenekeci explains, “Despite being limited to 1,824 spindles, Toyota’s compact ring machines produce more and higher-quality yarn than even the longest machines offered by competitors. Their performance, combined with low maintenance requirements and high adaptability, gives us a clear edge.”

The final step is handled by the Muratec FPRO EX automatic winder, seamlessly connected via Coner Link. This configuration ensures smooth yarn transfer, minimal contamination, and consistently high winding quality, completing a process chain in which every detail is aligned for excellence.

Collaboration at its finest: three leading technologies working hand in hand for one shared goal – perfect yarn quality.

The mill produces 18.5 tonnes of premium combed ring yarn daily in counts of Ne 20, 24, and 30, primarily for knitting applications. Although the focus is on locally grown cotton , which typically exhibits greater variability in fibre properties, the mill successfully manufactures yarns that are in high demand in both domestic markets with stringent quality standards and international export markets.

This commitment to excellence has not gone unnoticed. Pinter, 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 outstanding fibre preparation. This achievement underscores the effectiveness of combining top-tier machinery from Trützschler, Toyota and Murata.

Toyota and Zirve experts exchanging insights on roving technology for superior quality at low twist levels.

Strategic choice for excellence: Erhan Tenekeci, General Manager of Zirve, combines the best technologies from Trützschler, Toyota, and Murata to achieve outstanding yarn quality.

Collaboration without compromise — the best of all worlds
This project demonstrates that integrating machinery from different manufacturers can be done and done successfully. The planning phase was smooth and collaborative, with all partners working closely together. The result is a production line that is more than the sum of its parts, with each machine contributing to a shared objective: perfect yarn quality.

It is a compelling example of what can be achieved when openness, technical excellence, and strategic thinking come together. By selecting the best solution for each stage regardless of brand, Zirve Tekstil has set a benchmark for modern spinning.

“The best from every machine, for the best from every fibre.”