Suessen COMPACTeasy is helping spinning mills improve yarn quality, reduce hairiness and increase production efficiency without additional energy consumption. Badsha Group, one of Bangladesh’s largest textile manufacturers with 700,000 spindles, achieved productivity gains of more than 6% after implementing the COMPACTeasy compact spinning system across 90,000 spindles. The solution delivered stable compact yarn quality, improved Uster values and higher spinning speeds while maintaining process reliability and minimizing maintenance complexity.
Badsha Group, one of Bangladesh’s largest textile manufacturers, aimed to meet rising international quality requirements and increase productivity in compact spinning – all without additional complexity or cost. Suessen’s COMPACTeasy proved to be the ideal solution.
With 700 000 spindles, Badsha Group is a leading force in Bangladesh’s textile industry. Its mills – Badsha Textiles and Kamal Yarn – are specialized in producing 100% cotton yarns for the demanding knitting market, typically in the Ne 28 range.
Wanted: A Smarter Compacting Solution
Operating in a highly competitive environment, Badsha Group faces buyers who expect superior yarn quality, consistent uniformity, low hairiness, and stable processes.
To remain competitive and address these rising demands, the company sought a solution that could deliver higher and reproducible compact yarn quality across multiple plants. Additional requirements were:
- easy to operate, without complex technology
- minimal maintenance
- no additional energy consumption
At the same time, process reliability had to remain uncompromised, and productivity gains had to be measurable.
Impressive Productivity Gains with Suessen COMPACTeasy
As COMPACTeasy met all key criteria, Badsha Group decided to implement Suessen’s mechanical compacting system on around 90 000 spindles at the Badsha Textiles and Kamal Yarn spinning mills.
The benefits became apparent shortly after installation: using identical raw materials and nearly identical settings, both plants achieved increases in production of more than 6% with stable yarn values.
- Badsha Textiles produce Ne 20 carded yarn at a speed of 14 700 rpm with an efficiency of 95%, resulting in a productivity increase of 6.94% compared to conventional spinning.
- Kamal Yarn produces Ne 26 combed yarn at 17 000 rpm with an efficiency of 96%, achieving a productivity increase of 6.20%.
Productivity performance overview
| Badsha Textiles | Kamal Yarn | |
|---|---|---|
| Number of COMPACTeasy Units | 96 × 516 | 40 × 1008 |
| Yarn Count | Ne 20 carded | Ne 26 combed |
| Speed (rpm) | 14 700 | 17 000 |
| Efficiency | 95% | 96% |
| Productivity Increase | +6.94% | +6.20% |
Improved Yarn Quality and Process Stability Across Both Mills
Both plants also benefit from:
- significantly reduced hairiness
- improved Uster values
- stable compact quality regardless of operating personnel
- enhanced process reliability
- higher spinning speeds without any loss of quality
All of this comes without additional energy consumption and ensures a fast payback period through productivity gains.
Simple, Reliable, High‑Performing Compacting Device
Suessen COMPACTeasy delivers exactly what Badsha Group was looking for. “With COMPACTeasy, we have found a solution that simply works – every day and in every position,” said Khorshed Alam, Executive Director at Badsha Group. “The quality is consistent, hairiness is significantly reduced, and we are achieving a measurable increase in productivity.”
He continued: “Particularly important for us: no additional complexity, no extra maintenance, and a very good ROI. Our teams enjoy working with it because it is reliable and uncomplicated. COMPACTeasy gives us the security our customers expect.”
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