One of the world’s biggest yarn-makers, KORTEKS commenced operation in 1989 with the manufacture of yarns under the “TAÇ YARN” name.
A Lurgi GmbH project
The original construction and installation works were carried out by Lurgi GmbH, after which production of yarns under the “TAÇ YARN” name began in 21,440 m2 of factory space.
Production of partially-oriented polyester yarn (POY) from chips begins with a production capacity of 18 tons/day.
With the completion of the Emre Project in 1990 a polycondensation plant was installed with an initial production capacity of 65 tons/day. This was later increased to 80 tons/day.
Construction work on the Berkun Project to build KORTEKS’s second plant began in 1997. With a total of 123,398 m2 of manufacturing space, the plant was commissioned and went into operation after just 27 months: 18 for construction and 9 for mechanical installation.
Construction of the factory’s MEG tanks is completed. By enabling the company to store raw materials sufficient to keep its operations going for up to a month, these tanks significantly reduce KORTEKS’s dependence on suppliers.
KORTEKS’s polycondensation, POY, and FDY (fully-drawn yarn) units commence production. The result is the world’s biggest-capacity single-line continuous polycondensation + direct melt-feed POY-FDY manufacturing facility.
The twisting and fixing vat is installed. The project’s 44,000 m2 of manufacturing space and 22,000 kg/day capacity enable the company to expand its product range from flat and texturized yarns to twist, crepe yarns, Knit de Knit (KDK)-Lezzeni yarns, shaggy yarns, and fancy, embroidery yarns.
Installation of the Muratec machinery is completed. With a total texturized yarn production capacity of 110 tons/day in 50,000 m2 of manufacturing space, these machines are equipped with an online process control system.
R&D / P&D pilot machinery is installed in order to further diversify production by allowing new products to be added to the portfolio. These machines are designed so as to quickly turn out small quantities of new yarns on a trial basis according to customers’ sample requests.
POY packaging operations are automated and POY package weights are increased to 20 kgs. This makes it possible to minimize human error, increase customer satisfaction, save time, and protect product quality by eliminating the need for hand-wrapping.
With the installation and commissioning of air texturizing machines that make it possible to manufacture yarns with different weights and filament counts, the company is able serve a wider range of customers making goods like carpets and automotive
AFK texturizing machinery is installed and commissioned. Thanks to such features as micro- and super-micro production, automatic mounting, command metric production, and online process control, manufacturing is made much more efficient and error-free.
KORTEKS engineers complete the installing of a texture-sorting automated packaging system that makes it possible to minimize human error, save time, and protect product quality by eliminating the need for hand-wrapping.
A monofilament separation and bobbin dyeing plant is installed. This permits the manufacturing of 20/1-30/1 weight fine yarns and gives KORTEKS the ability to satisfy customers’ demand for hank-dyed products, thereby sparing them the need to outsource the process themselves.
A masterbatch production system is installed and commissioned and manufacturing begins. This new system makes it possible to increase color diversity in dope dyed color-fast yarns while also reducing the company’s dependence on dye suppliers.
Colored production capacity is increased in dope dyed yarns.
Work begins on a project to set up an in-house KORTEKS R&D Center.
Work begins on the installation of 35 new-generation texturizing machines.
The KORTEKS R&D Center is audited and licensed by the Ministry of Science, Industry and Technology.
New generation texturizing machines have been installed.
Polymer Recycling Facility which we have started with its construction in 2020, became operational.
The United Nations Global Compact, the world's largest corporate sustainability initiative, was signed.
The first Sustainability Report of Zorlu Textiles Group was published.
The first EPD certificates were published in the polyester yarn sector by completing the Life Cycle Analysis studies of all processes carried out in the name of sustainability.
Batch-Poly plant implementation was completed within the scope of the R&D Center.
The Automated Warehouse project was completed in order to autonomize the business processes. With the implementation of the automated warehouse project, significant benefits were achieved in storage activities such as "optimum energy efficiency, higher capacity in less square meters with the advantage of vertical growth instead of horizontal storage space, fast inventory control, fast order preparation and much leaner business processes".
Implementation of new generation 3 POY and 8 texturing machines were completed.
With the PLASTICE Project, we were accepted to the Horizon Europe Green Deal Program, where the European Union conducts research, development and innovation projects. PLASTICE, Korteks' first Horizon Europe Project, aims to recycle complex textile and plastic wastes, which are very difficult to separate, and to contribute to the circular economy by manufacturing final products with low carbon footprint from recycled raw materials.
We have been accepted by the European Commission for our 2nd Horizon Europe project on Safe and Sustainable Design. The strategic objective of the project is to introduce screening and testing methods for the development of safe and sustainable materials in three relevant application areas: textile, automotive and cosmetics industry. Textile activities will be managed in the project.
2 new generation FDY machines started to operations.