Complete Econtrol for Istanbul
Through investment in new Monforts technology, Istanbul
Boyahanesi is planning to increase its capacity for the
commission dyeing and finishing of woven goods to a monthly 2.5
million square metres during 2019.
The company is surely also the only dyehouse in Turkey to
date with its own proprietary software for virtual control of
all operations via smartphone or TV from the boardroom.
The special app-based programme has been developed by
co-founder and director Kemal Taşkin, who has a background in
software engineering, and it provides real-time information on
all machine parameters and operator activity.
The Monforts Thermex Econtrol continuous dyeing line
at Istanbul Boyahanesi.
“I am now developing it further and in the near-future it
will also be able to provide financial forecasting for us right
down to individual batch level,” he says.
This development has much in common with the advances
Monforts is making itself in the field of Industry 4.0 and
automation, such as the latest Qualitex 800 control system and
the Web-UI app for remote visualisation of Monforts technologies
via smart phones and tablet devices.
Istanbul Boyahanesi Plant Manager, Hakan Kaplan
Co-Founder and Director, Kemal Taskin.
Based in the key Turkish textile centre of Çerkezköy,
Istanbul Boyahanesi was only founded in 2017, on the site of an
older existing dyehouse. It is a joint venture between two of
Turkey’s leading textile wholesalers, Yilmaz Kumaşçilik, which
specialises in fabrics for casual and outerwear, and shirtings
and suitings textiles operation Erika Kumaşçilik.
Immediately on its formation, the first move of the new
company was to order a new Monforts Thermex Econtrol continuous
“The existing equipment we inherited, which includes a
23-year-old Monforts Montex stenter, is only suitable for
producing heavy weight fabrics with weights of 300gsm and
above,” Mr Taşkin explains. “The new Thermex allows us to get
down to fabric weights of 80gsm. The old pad dyeing system we
have is also very time-consuming and the Thermex has allowed us
to considerably shorten processing times for the heavier
fabrics, while at the same time considerably expanding our
product offering. It’s an extremely versatile range, allowing us
to instantly see the results and to easily move between reactive
and disperse dyeing, for example.”
Dahboard of Istanbul Boyahanesi’s proprietary
app-based plant control programme developed by
Co-founder and Director, Kemal Taskin.
“Of course, there is no comparison in terms of chemicals and
energy usage and with the Thermex the savings are considerable,”
adds plant manager Hakan Kaplan. “It is also allowing us to make
much longer batches of fabrics.”
The Thermex Econtrol range has a working width of 1.8 metres
and allows the single-bath continuous dyeing of cotton and
polyester fabrics with selected reactive and dispersion
dyestuffs, as well as cotton-polyester blends to be processed
without reductive intermediate cleaning, eliminating the need
for a steamer.
Other processes, such as the use of indanthren vat dyes for
enhanced wash and boil fastness, or the over-dyeing on
reactive-dyed cotton fabrics to achieve an extremely broad range
of colour effects, are also carried out on the range.
The range was installed and commissioned in a very tight
space within the existing factory by Istanbul-based Monforts
partner Neotek Tekstil, which is also a new company, formed in
February 2016 to assume responsibility for Monforts dyeing and
finishing technology throughout Turkey.
In the short period since its inception, Neotek has already
installed and commissioned over 50 full Monforts ranges
throughout the country.
Istanbul Boyahanesi plant.
“The Monforts Montex stenter is of course, our key product
and its advantages are well established,” says Neotek founder
Ahmet Kiliç. “It allows our customers to achieve high quality
continuously, with the trusted electronic drive technology of
Monforts. With the energy savings that are achieved they also
save money and being robust, Monforts stenters also require
fewer spare parts and less maintenance, with remote assistance
in any case always available.
“All of the components in Monforts machines are the best
available and the majority of the companies in Turkey either
already have experience with them and trust the brand, or see
the benchmarks being set by their competitors, making Monforts
technology the natural choice,” he adds.
“We have been very happy with the service we have received to
date from Monforts and Neotek, and will continue to trust their
technology going forward as we expand our business,” Mr Taşkin