Mogul, which is the first in Turkey to begin the production of spunbond, meltblown, bi-component, microfilaments and SMS, is the first member of EDANA (European Nonwoven Association) from Turkey. With the large portion of the capacity to export to 56 countries around the world Mogul, is among the first 1,000 exporting companies and industrial organizations in Turkey. Since 2013, Mogul has been one of the top 40 nonwovens manufacturers in the world and has been granted the INDA Special Entrepreneurship Special Award in 2001 and 2016 for its rapid growth.
Turkey’s first producing microfilaments of the fabric Madaline® opened a new era in the garment industry. Mogul Company’s Sales Director Murat Pırasacı shares the details of the Madaline® fabric with our readers.
Would you please share with our readers your branded success in the nonwoven sector and the establishment stage of the company?
Founded in 1997, Mogul is a family-owned company that operates in Gaziantep. The field of activity of the company is the production and sale of nonwoven fabrics, composite fabrics and certain finished products. Mogul management center and 1st production facility is located in Gaziantep Second Organized Industrial Zone and the second production facility was opened in 2007 in Gaziantep Third Organized Industrial Zone. It was put into service in 2002 in Istanbul Bayrampaşa for domestic sales and storage. A new facility investment has been initiated in Lüleburgaz and the first production line has been activated in the second quarter of 2016. In addition, the production facility in the US State of South Carolina was commissioned in March 2017. 4. Approximately 500 employees are employed in 4 facilites. Mogul’s product portfolio includes spunlace, PP spunbond, PET spunbond, meltblown, SMS and composites (SM-MMM-SMM) extrusion coating / laminated fabrics, Peva Film and some final products produced from them. Main sectors of fabric supply include cleaning cloth, wet wipes, construction sector, oil-absorbing products, filtration, coating / lamination linings, furniture / mattress industry, packaging, automotive, agriculture, hygiene, medical, cable insulation, vacuum cleaner dust bag and softener pads.
Could you please tell us a little about the fabric production of the new Microfilament product from Mogul?
Madaline®, which is one of the two technologies that are produced with a patent by Mogul is opening a new era in the garment industry. Madaline® fabric production, which is produced by a continious process that is controlled by cameras and compatible with American NCSU patented technology and Industry 4.0 norms. Considering that conventional yarn-weaving and knitting processes are produced in the process extending from several hours to weeks depending on integration, it provides an incredible speed. This can be considered to be an answer to the concept of fast fashion today.
“Fashion is the second most polluting industry after oil.”
Water-borne chemicals cause contamination of water resources and damage to habitat in that area. Carbon emissions are equivalent to global aviation industry. The fashion industry alone accounts for 5% of global carbon emissions, which is quite striking and high. At the end of the same year, 60% of produced textile products are either consumption surplus or turning into waste.
The Madaline® fabric is normally made with water and drying energy through finishing processes, and the Madaline® process has a minimal level of carbon footprint due to the production speed during the production process and the production speed in a single step, and significantly reduces the environmental impact compared to conventional fabrics.
Madaline® is performance-oriented and therefore requires less fabric in order to achieve similar performance compared to traditional textiles, which means both cost-effective and less environmental impact.
Another concept studied for Madaline® is to reduce the carbon footprint by using recycled raw materials and to adapt to the ever-expanding circular fashion concept.
In terms of the environment, it is important to note that Madaline® is a very low-hair fabric and does not release fibers to the nature in the wash. Conventional microfiber fabrics can leave ve grams nehir of microfibre in each wash cycle. These microfibers go to treatment plants with waste water, and up to 40% of them are mixed with rivers, lakes and oceans to join the food chain of aquatic organisms. Madaline® can reduce the entry of fiber plastics into our food chain to support and improve our well-being.
Infinite microfilaments that are 100 times thinner than human hair are needled with water in order to obtain a uniform and non-feathered fabric with versatile durability.
“Madaline® has unique and attractive features such as being light and compact, breathable with good moisture management, no hairiness, good thermal insulation, no wrinkling and quick drying.”
The shape memory provides a permanent three-dimensional structure with heat and pressure, and the non-fringing structure on the edges of the patterning allows the fabric to be made without the seam and the edge stitching of the fabric. In clothing applications, sweat vapor is sent away from the body, but the dense structure of the fabric prevents bacteria and microorganisms from entering and staying in the fabric. As moisture is rapidly discharged and bacteria are prevented from entering, odors are also prevented from occurring due to bacterial growth and thus a dry and clean feeling is obtained. Unprocessed Madaline® absorbs up to 200% of its own weight in the water and, together with the hydrophilic process, can absorb this up to 500%. This is 70% more than the absorption of conventional textiles. Even if it absorbs, Madaline® quickly evaporates moisture by means of micro-channels in the fabric. As a consequence, while providing a serious absorption, Madaline®, which dries quite fast, has excellent moisture management properties. This provides a serious advantage in areas such as bathrobes, towels, cleaning cloth and active wear.
Madaline® is a naturally-occurring hypoallergenic product that protects patients from dust mite allergy against complete relief and the spread of board dryness. Madeline® has been awarded the ECARF ‘Allergy-Friendly Products and Services’ certificate, which is recognized worldwide.
Thanks to its improved performance, Madaline® can be used in a wide range of applications such as Home Textile Products, Clothing, Cleaning, Hygiene and Medical Areas, Technical Packaging, Graphics and Printing grounds, Automotive and Aerospace, Acoustics, Filtering, Food Contact, Labels, as well as apparel applications.
You produce Turkey’s first microfilaments fabric. How were the reflections of such an innovation in Turkey and the world?
Madaline® fabric is a value-added product and creates an important input for the textile sector in creating high quality and high value added export products. Besides, it has started to be used in many sectors as import substitution in its industrial applications and it helps us to close our current account deficit.
Can you give information about the usage areas of your products in technical textiles?
Due to the special structure of the Madaline® fabric, we can provide thermal comfort with less amount of Madaline®. It also offers unique advantages to personal clothing from home textiles, with a 94.5% bacteria filter feature without any chemicals being used. Clothing products made of Madaline® fabric do not smell sweat.
What makes your products sustainable?
Our Lüleburgaz facility, where we produce Madaline® fabric, produces in accordance with industry 4.0 norms. It is very important to have a minimum environmental impact in the process of product completion and use and not to contaminate the food chain at the microparticle level. If we consider that a total of 10,800 liters of water is used to produce one kilogram of denim fabric, we have to use our resources more effectively globally.
What are your thoughts about Turkey’s situation and prospects in the Nonwovens industry?
Nonwoven industry over the past 10 years has shown an extremely serious development and Turkey has become a major player in the world. Capacity in Turkey as well as Europe moved to second after Germany in history of this sector in Turkey and Europe is a significant achievement considering. The current capacity necessitates the exporters to make a significant amount of exports. There is also growing rapidly in use nonwoven in Turkey. the relative advantage of the installed machine park in Turkey to be new. In the event that different technologies and value-added yönelip investment in Turkey will continue to be an important player.
You’re one of the most important companies in Turkey that exports. How much of your products are being exported? Which products of you are in the foreground?
Mogul exports 60% of our production. We also commissioned our investment in South Caroline USA in 2017. Mogul has the widest range of nonwoven products using different technologies. The world is in the top 40 in nonwovens. Our export products have a wide range of products ranging from medical, automotive, environmental, agricultural, aeropace, footwear, furniture, digital printing, and textile.
How has Mogul spent the year 2018? Can we get your 2018 assessment?
The fluctuation in foreign exchange and raw material prices in 2018 was also seen in the nonwovens sector, like any other sector. We can evaluate our effectiveness in export markets as a year where we increase our activity even further. As Mogul, our most important step was to start the use of the Madaline® fabric we produced in our Lüleburgaz facilities in different sectors. The cooperation initiated on the subject will show its effect more effectively in the coming years.
What are Mogul’s goals in the coming period?
As a company that always invests in innovative products and technologies, Mogul will consolidate this innovative position in the nonwoven industry. We aim to increase the usage areas by expanding the usage areas and cooperation of Madaline® fabric.
What can you say about your expectations for 2019?
It is foreseen that 2019 will be economically difficult for our country. Therefore, we can foresee that there will be some contraction in the domestic market. Firms will mainly try to develop export markets This may lead to price competition and profit erosion. Increasing customs rates with China can create opportunities in the American market.