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Korteks breaks new ground for Turkey

The line has a production capacity of 7,200 tons per year and currently processes clean in-house polyester fibres and post-consumer PET flakes.

15th September 2021

Innovation in Textiles
 |  Bursa, Turkey


Korteks, one of the world’s biggest yarn producers based in Bursa, Turkey, has started the production of recycled polyester filament yarn in using a Starlinger recycling line.

The Starlinger recoSTAR universal 165 H-VAC iV+, which is part of a $10 million investment by Koreks in a new polymer recycling facility, became operational in May. It has a production capacity of 7,200 tons per year and currently processes clean in-house polyester fibres from production scrap together with washed post-consumer PET flakes at a ratio of 50/50.

Korteks uses the polyester regranulate at a share of 100% for its new polyester filament yarn line it is will market under the name TAÇ Reborn.

“We have been in extensive cooperation with Starlinger for a long time” said Barış Mert, Korteks general manager. “Thanks to their unique and innovative recycling technology we can offer new products in line with the circular economy model. That’s why, as Europe’s largest integrated and innovative polyester yarn producer, we are very pleased to work with Starlinger, the market leader in PET and polyester recycling and refining.”

Rapid sleeve changer

The Starlinger recycling line is the first of its kind in Turkey and is equipped with special components for filament yarn recycling. An RSC (rapid sleeve changer) candle filter developed by Starlinger ensures the finest melt filtration down to 15 μm. It has been specially designed for polyester recycling and reaches an output of 1,000 kg/h. For continuous operation, the filter elements are changed “on the fly” without interrupting production, which significantly limits melt loss.

Korteks recycles polyester filament yarn waste and PET bottle flakes. © Korteks

The viscoSTAR SSP unit at the end of the recycling process guarantees consistent IV increase according to the first-in-first-out principle. This makes sure that the produced regranulate has the ideal properties required for filament yarn production. The technical configuration of the line not only allows the processing of a polyester fibre/PET flake mix as input materials, but also 100% polyester filament scrap or 100% PET bottle flakes.

With the new recycling facility, which comprises a total closed area of 17,000 square metres and has a monthly production capacity of 600 tons, Korteks has been able to reduce the production waste at its virgin PES yarn site to zero.

“We are proud to be a partner in Korteks’ quest for more sustainability in the textile business,” said Paul Niedl, Commercial Head of Starlinger recycling technology. “Turkey is a significant global player in this industry. If more and more Turkish textile manufacturers start using recycled materials, this will be an important signal for the sector and a big step towards a circular economy. We support this development with our extensive know-how in synthetic fibre recycling and supply the fine-tuned and reliable recycling technology required in this field.”

Korteks expects the recycling market in general to grow as there is increased acceptance for recycled products, and predicts the need for recycling solutions also for other synthetic and natural fibres.

Setting the agenda

“The period of the pandemic that the world has been going through has once again strikingly revealed the necessity of building a sustainable living together,” said Mert. “The textile industry is also deeply affected by this big transformation. We believe that those who can manage this change well will also set the global textile agenda in the future. With this belief, we carried out the polyester recycling facility project with an investment of ren million dollars. Thanks to this project, we broke new ground in Turkey and can produce polyester filament yarn from 100% PET bottles. Having Starlinger at our side as a business partner gives us strength in our long-term journey towards sustainability.”

TAÇ Reborn polyester yarns are used in a wide variety of applications. © Korteks

Starlinger recycling technology is a division of Austrian-based Starlinger, a world market leader in the field of machinery and complete lines for woven plastic packaging production. For more than 30 years Starlinger recycling technology has been providing machinery solutions for the recycling and refining of a wide range of plastics such as PE, PP, PA, PS, BOPP and PET. Starlinger PET recycling systems produce food-safe rPET and are approved for use in food applications by many brand owners as well as various national and international authorities.

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