Beşler Tekstil Reached 11% Higher Productivity with Circular Comb Upgrade
Beşler Tekstil, Türkiye, is a leading manufacturer of compact cotton yarn with many years of operational expertise and a monthly production of around 1 800 tons. The company modernized its 18-year-old combers E 65 with Rieter’s 130° circular comb technology. The upgrade enabled 11% increase in productivity, improved sliver and yarn quality, reduced maintenance requirements and extended machine lifetime.
Combing is the quality gate in spinning because it removes everything that compromises strength, uniformity and fabric appearance. That is why the comber performance plays a critical role in producing high-quality combed cotton yarn.
Beşler Tekstil in Türkiye operates a wide range of Rieter combers, from older to the latest generation machines, including E 62, E 65, E 80, and E 86. While the combers E 62 and E 65 had been operating reliably for nearly 18 years, their productivity and quality performance at 500 nips/min could not match the latest-generation comber E 86. To maintain the required yarn quality level, the customer had to operate the E 65 machines at a reduced speed.
With its latest comber models E 80 and E 85, Beşler is satisfied with the results obtained from the 130° circular comb technology. Therefore, the customer approached Rieter to evaluate a modernization solution for the existing E 65 machines with the goal to achieve productivity and quality levels comparable to those of newer-generation combers.
Modernizing Comber E 65 from 90 to 130° Circular Comb
The goal for Beşler was to meet the needs of cotton spinners in the Turkish market and achieve the targeted improvements in productivity, quality and operational efficiency. Based on this requirements, the Rieter Engineered Solutions team developed a comprehensive technology upgrade package to convert the E 65 with 90° circular comb to an advanced 130° combing technology.
The upgrade goes beyond a simple change of the circular comb package, as such a standalone conversion would not deliver the full performance benefits. To fully leverage the advantages of 130° combing technology, the package includes the Ri-Q-Comb i500 flex for an increased combing area, as well as the replacement and integration of key technological components. These include the nipper, top comb, comb support, calender module, detaching roller cots, AIRshield, guiding segment elements, ratchet wheels and cleaning brushes.
Converting nearly 18 years old models of combers to an advanced 130° combing technology has brought a significant improvement in our yarn quality.Ertuğrul Terkeşli, Maintenance Chief of Beşler Tekstil
Less Imperfections, Higher Productivity
“After the upgrade, we have seen a significant improvement in our yarn quality. When comparing approximately 18-year-old machines with new machines, we observed that the quality is at par. In addition, the replacement of parts has also increased our machine lifetime,” says, Ertuğrul Terkeşli, Maintenance Chief of Beşler Tekstil.
11% Higher Productivity with Better Sliver and Yarn Quality
Following the 130° circular comb platform upgrade, the customer achieved the following measurable improvements:
- 11% increase in productivity, with speed increased from 450 nips/min to 500 nips/min,
- sliver unevenness U% reduced by 28%, with a 34% reduction in sliver CVm%,
- 63% reduction in yarn imperfections and
- 7% reduction in yarn hairiness index H.
These improvements were achieved with only a marginal increase in noil extraction of 0.5%, demonstrating the effectiveness of the upgraded combing technology. Even at the same noil extraction level, measurable improvements in sliver and yarn quality can be achieved through the upgraded technology package.
Additionally, maintenance requirements have decreased due to the replacement of critical technological components, leading to improved machine efficiency and higher utilization. The upgrade enables the 18-year-old E 65 machines to achieve productivity and quality performance comparable to that of modern-generation combers.
Energy consumption has been optimized, while overall efficiency and product quality have significantly improved. Furthermore, the lifetime of both machine components and the machine itself have been extended through cost-effective part replacement. The 90° to 130° circular comb platform upgrade is available for the E 65, E 75, E 66 and E 76 comber models.
Through this Rieter upgrade, spinning mills can improve productivity and quality, optimize raw material utilization, extend machine lifetime and enhance long-term competitiveness with a cost-effective modernization solution.
About Beşler Tekstil
Beşler Tekstil San. Tic. A.Ş., located in Kayseri, Türkiye, was established in 1997 with an initial capacity of 21 600 spindles. Over the years, the company has steadily expanded its operations, reaching a total capacity of 82 752 spindles. Beşler Tekstil is a leading manufacturer of cotton yarn, leveraging advanced Rieter spinning technology, particularly for high-capacity compact yarn production. With years of operational expertise, the company has significantly strengthened its capabilities in producing 100% cotton compact yarn, covering a yarn count range from Ne 16/1 to Ne 40/1. Today, Beşler Tekstil has a production capacity of approximately 1 800 tons per month.