Gama Recycle - a recycling pioneer

When Zafer Kaplan founded Gama Recycle Sustainable Technologies in Gaziantep in 1997, he was a pioneer with a vision to improve the sustainability of the Turkish textile industry. Today, Gama is one of the largest players in the global market for yarns made from recycled or regenerated fibres. For more than two decades, Gama has relied on Saurer's Autocoro to process its mechanically recycled fibres into yarns used by many international brands for sustainable fashion.

Driven by his belief that little steps can change the world, Zafer Kaplan founded Gama Recycle to protect the world's natural resources. When he came up with the idea of recycling the leftovers from clothing production, he was one of the first to process recycled fibres for fashion. Processing the short, mechannically recycled fibres, is a great challenge, because the fibre length and quality is not consistent. 

Gama, a trendsetter in sustainability, now has 6 production facilities in Turkey. Every day, more than 1,500 employees recycle around 300 tonnes of PET bottles and 200 tonnes of used clothing and fabric scraps into yarn and textile products and PET chips. As consumer demand for 'green fashion' increases worldwide, Gama Recycle continues to grow and exports around 40% of its production to more than 30 countries. 

“To save energy is an important part of our mission to produce yarns sustainably. With our latest Autocoro 10 we reduce the energy requirement of the OE yarns by up to 20% compared to the previous machines.“
Zafer Kaplan
CEO and owner Gama Recycle

Vision of protecting natural resources

Zafer Kaplan's vision was to grow and "protect nature by moving forward with an environmentally friendly approach, increasing the amount of textile and plastic bottle waste processed in production and returning it to the economy". Recycling saves energy, water, dyes, mineral oil and virgin fibres and is lucrative on the other hand, because of the low raw material costs.

Giving fibres a second life

Gama was looking for machines and technologies that could handle high short fibre content, high fibre fly and low energy consumption. Recycled fibre is not as strong as virgin fibre and has been stressed during its first life and during the opening of the fabric. Therefore, in its second life, the fibre needs to be processed carefully to provide sufficient yarn quality. The secret of Gama's success is to spin from extremely variable raw material a consistent yarn quality.

Rotor-spinning - the right solution

The Saurer Autocoro rotor spinning machine is ideal for processing short recycled fibres and Gama Recycle now has around 3,000 Autocoro spinning positions in use. At Gama Recycle, about 80% of the regenerated fibres are processed as rotor yarns. Saurer supports its customers in defining the correct machine settings and elements such as rotors, opening rollers and nozzles. This support made Gama's entry into OE yarn production easy.  

Over the years, Gama Recycle has developed specific know-how and technologies for the processing of recycled and regenerated fibres and has protected its know-how with 23 patents. In 2002, Gama invested in the latest generation of Saurer rotor spinning machines - the Autocoro 10 - to benefit from 20% energy savings compared to the previous model.

Zusätzliche DCUs Autocoro Upgrade

Benefits of Autocoro 10 for recycled fibres

Cost savings thanks to 20 % energy savings are the main reason for Gamas's decision to go for Autocoro 10. But there are additional benefits, which only Autocoro can offer:

  • Individual drive technology of each spinning unit to produce different lots on one machine.
  • 8 DCUs (Doffing Cleaning Unit) per machine to ensure high cleaning capacity.
  • With recycled fibre materials a high piecing capacity is required because more breaks occur. Synchropiecing 36 allows 36 piecings at the same time.
  • Multilot function and seamless lot change for increased production flexibility, e.g. to manage urgent customer orders. 
  • Yarn clearer Corolab to assure yarn and piecing quality at each spinning position and to control every metre of yarn.
Customer details
LocationGaziantep, Türkiye
Saurer installation3 000 Autocoro spinning positions
Yarn detailsYarns from regenerated fibres, Ne 8/1 to Ne 47/1, twisting up to 20ply yarn, 100% cotton and blends.
Yarns from recycled fibres, Ne1/1 to Ne 20/1, twisting up to 20ply yarn, 100% cotton and blends.
PES Staple fibres, 1.2 to 20 den, cut length 28-153 mm
Sustainability brandsTReC, Closed Loop, Petman®, r-PET
Spinning capacity120 000 tons of regenerated and recycled fibres
Recycling capacity2.9 million PET bottles daily (300 tonnes)
372 000 pieces of garments daily (200 tonnes)
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