Mogul
Gaziantep, Turkey
www.mogulsb.com
2013 Nonwovens Sales: $113 million
Key Personnel
Ekrem Kayali, chairman; C.Enver Kayali, president; Ayse Kayali, executive board member; Serkan Gogus, CEO; Ersin Kosker, director of projects and operations
Plants
Gaziantep, Turkey
Processes
Spunbond, meltblown, spunlace, laminated fabrics, films, welded fabrics, converting
Major Markets
Bedding and furniture, medical, agriculture-landscape, luggage & shoe linings, filtration, oil sorbents/spill control, wipes, protective apparel, construction, hygiene, automotive, fabric softeners, laminating/coating substrates, packaging, vacuum cleaner dustbags
Mogul Tekstil Sanayi ve Ticaret Ltd.Sti. is a Turkish-based private company located in Gaziantep in southeast Turkey. It was founded in 1996 and began operations in 1997 to produce and market nonwovens and composites.
The company’s product range comprises 100% polypropylene spunbond nonwovens, polyester spunbond nonwovens, meltblown nonwovens, spunlace nonwovens, extrusion coated/laminated fabrics, PVA film and converted products made from nonwovens and composites.
Mogul was the first company to start spunbond, meltblown, SMS production in Turkey and is currently exporting the majority of its capacity to more than 40 countries on four continents on a global basis. Mogul is ranked among the top 1,000 exporter companies and industrial companies (for turnover) in Turkey. Mogul was also the first member of EDANA from Turkey.
Since its establishment, Mogul has regularly invested in its business. Its most recent investment was a new core/sheath bicomponent PET/CoET spunbond line, which began operation in late 2013. Mogul’s first bico line, the investment enhanced its wide range of product offerings to include thermal bonded falt fabrics in round and trilobal filament shapes in low denierts. This line will mainly target industrial applications with products sold under the Buffalo brand name.
Mogul also operates two mono PET spunbond lines, the most recent of which was added in 2010, and the company’s total capacity in spunbond is now 15,000 tons.
Another focus area in recent years has been spunlace and the company now operates two lines, added in 2010 and 2011, which together make 24,000 tons of lightweight spunlace nonwovens. Mogul entered the spunlace market to diversify its product range outside of industrial applications and mainly targets the global wet wipes market with this output.
All of these investments have contributed to impressive growth for Mogul. Sales grew from $38 million to $113 million between 2008 and 2012.
www.mogulsb.com
2013 Nonwovens Sales: $113 million
Key Personnel
Ekrem Kayali, chairman; C.Enver Kayali, president; Ayse Kayali, executive board member; Serkan Gogus, CEO; Ersin Kosker, director of projects and operations
Plants
Gaziantep, Turkey
Processes
Spunbond, meltblown, spunlace, laminated fabrics, films, welded fabrics, converting
Major Markets
Bedding and furniture, medical, agriculture-landscape, luggage & shoe linings, filtration, oil sorbents/spill control, wipes, protective apparel, construction, hygiene, automotive, fabric softeners, laminating/coating substrates, packaging, vacuum cleaner dustbags
Mogul Tekstil Sanayi ve Ticaret Ltd.Sti. is a Turkish-based private company located in Gaziantep in southeast Turkey. It was founded in 1996 and began operations in 1997 to produce and market nonwovens and composites.
The company’s product range comprises 100% polypropylene spunbond nonwovens, polyester spunbond nonwovens, meltblown nonwovens, spunlace nonwovens, extrusion coated/laminated fabrics, PVA film and converted products made from nonwovens and composites.
Mogul was the first company to start spunbond, meltblown, SMS production in Turkey and is currently exporting the majority of its capacity to more than 40 countries on four continents on a global basis. Mogul is ranked among the top 1,000 exporter companies and industrial companies (for turnover) in Turkey. Mogul was also the first member of EDANA from Turkey.
Since its establishment, Mogul has regularly invested in its business. Its most recent investment was a new core/sheath bicomponent PET/CoET spunbond line, which began operation in late 2013. Mogul’s first bico line, the investment enhanced its wide range of product offerings to include thermal bonded falt fabrics in round and trilobal filament shapes in low denierts. This line will mainly target industrial applications with products sold under the Buffalo brand name.
Mogul also operates two mono PET spunbond lines, the most recent of which was added in 2010, and the company’s total capacity in spunbond is now 15,000 tons.
Another focus area in recent years has been spunlace and the company now operates two lines, added in 2010 and 2011, which together make 24,000 tons of lightweight spunlace nonwovens. Mogul entered the spunlace market to diversify its product range outside of industrial applications and mainly targets the global wet wipes market with this output.
All of these investments have contributed to impressive growth for Mogul. Sales grew from $38 million to $113 million between 2008 and 2012.
Mogul
Gaziantep, Turkey
www.mogulsb.com
2014 Nonwovens Sales: $121 million
Key Personnel
Ekrem Kayali, chairman; C.Enver Kayali, president; Ayse Kayali, executive board member; Serkan Gogus, CEO; Ersin Kosker, director of projects and operations
Plants
Gaziantep, Turkey
Processes
Spunbond, meltblown, spunlace, laminated fabrics, films, welded fabrics, converting
Major Markets
Bedding and furniture, medical, agriculture-landscape, luggage & shoe linings, filtration, oil sorbents/spill control, wipes, protective apparel, construction, hygiene, automotive, fabric softeners, laminating/coating substrates, packaging, vacuum cleaner dustbags
Mogul Tekstil Sanayi ve Ticaret Ltd.Sti. is a Turkish-based private company located in Gaziantep in southeast Turkey. It was founded in 1996 and began operations in 1997 to produce and market nonwovens and composites.
The company’s product range comprises 100% polypropylene spunbond nonwovens, polyester spunbond nonwovens, meltblown nonwovens, spunlace nonwovens, extrusion coated/laminated fabrics, PVA film and converted products made from nonwovens and composites.
In August, Mogul announced it was establishing an operation in North America, its first overseas operations. The company is investing $17.6 million to construct a 91,000-square-foot building housing a spunlace line.
The plant, known as Mogul South Carolina Nonwovens, will be located in Gray Court, SC and will focus specifically on the production of spunlace nonwovens for medical, hygiene and personal wet wipes applications. Moving forward, Mogul expects to use its new facility to expand its entire product line.
The new site is expected to be operational by the second quarter of next year.
“Mogul is excited to launch its new North American operations in Laurens County, SC. Through our new facility in South Carolina, we will be able to better serve our North American customers with our diverse offerings of quality nonwoven products,” says Mogul founder and chairman Ekrem Kayali.
Mogul was the first company to start spunbond, meltblown, SMS production in Turkey and is currently exporting the majority of its capacity to more than 40 countries on four continents on a global basis. Mogul is ranked among the top 1,000 exporter companies and industrial companies (for turnover) in Turkey. Mogul was also the first member of EDANA from Turkey.
Since its establishment, Mogul has regularly invested in its business. Its most recent investment was a new core/sheath bicomponent PET/CoET spunbond line, which began operation in late 2013. Mogul’s first bico line, the investment enhanced its wide range of product offerings to include thermal bonded felt fabrics in round and trilobal filament shapes in low denierts. This line will mainly target industrial applications with products sold under the Buffalo brand name.
Mogul also operates two mono PET spunbond lines, the most recent of which was added in 2010, and the company’s total capacity in spunbond is now 15,000 tons.
Another focus area in recent years has been spunlace and the company now operates two lines, added in 2010 and 2011, which together make 24,000 tons of lightweight spunlace nonwovens. Mogul entered the spunlace market to diversify its product range outside of industrial applications and mainly targets the global wet wipes market with this output.
Gaziantep, Turkey
www.mogulsb.com
2014 Nonwovens Sales: $121 million
Key Personnel
Ekrem Kayali, chairman; C.Enver Kayali, president; Ayse Kayali, executive board member; Serkan Gogus, CEO; Ersin Kosker, director of projects and operations
Plants
Gaziantep, Turkey
Processes
Spunbond, meltblown, spunlace, laminated fabrics, films, welded fabrics, converting
Major Markets
Bedding and furniture, medical, agriculture-landscape, luggage & shoe linings, filtration, oil sorbents/spill control, wipes, protective apparel, construction, hygiene, automotive, fabric softeners, laminating/coating substrates, packaging, vacuum cleaner dustbags
Mogul Tekstil Sanayi ve Ticaret Ltd.Sti. is a Turkish-based private company located in Gaziantep in southeast Turkey. It was founded in 1996 and began operations in 1997 to produce and market nonwovens and composites.
The company’s product range comprises 100% polypropylene spunbond nonwovens, polyester spunbond nonwovens, meltblown nonwovens, spunlace nonwovens, extrusion coated/laminated fabrics, PVA film and converted products made from nonwovens and composites.
In August, Mogul announced it was establishing an operation in North America, its first overseas operations. The company is investing $17.6 million to construct a 91,000-square-foot building housing a spunlace line.
The plant, known as Mogul South Carolina Nonwovens, will be located in Gray Court, SC and will focus specifically on the production of spunlace nonwovens for medical, hygiene and personal wet wipes applications. Moving forward, Mogul expects to use its new facility to expand its entire product line.
The new site is expected to be operational by the second quarter of next year.
“Mogul is excited to launch its new North American operations in Laurens County, SC. Through our new facility in South Carolina, we will be able to better serve our North American customers with our diverse offerings of quality nonwoven products,” says Mogul founder and chairman Ekrem Kayali.
Mogul was the first company to start spunbond, meltblown, SMS production in Turkey and is currently exporting the majority of its capacity to more than 40 countries on four continents on a global basis. Mogul is ranked among the top 1,000 exporter companies and industrial companies (for turnover) in Turkey. Mogul was also the first member of EDANA from Turkey.
Since its establishment, Mogul has regularly invested in its business. Its most recent investment was a new core/sheath bicomponent PET/CoET spunbond line, which began operation in late 2013. Mogul’s first bico line, the investment enhanced its wide range of product offerings to include thermal bonded felt fabrics in round and trilobal filament shapes in low denierts. This line will mainly target industrial applications with products sold under the Buffalo brand name.
Mogul also operates two mono PET spunbond lines, the most recent of which was added in 2010, and the company’s total capacity in spunbond is now 15,000 tons.
Another focus area in recent years has been spunlace and the company now operates two lines, added in 2010 and 2011, which together make 24,000 tons of lightweight spunlace nonwovens. Mogul entered the spunlace market to diversify its product range outside of industrial applications and mainly targets the global wet wipes market with this output.
Gaziantep, Turkey
www.mogulsb.com
2015 Nonwovens Sales: $117 million
Key Personnel
Ekrem Kayali, chairman; C. Enver Kayali, president; Ayse Kayali, executive board member; Serkan Gogus, CEO; Murat G.Gökçe, general manager Durabey Istanbul plant, Darryl D.Fournier, president Mogul SC Nonwovens Corp; Ersin Kosker, director of projects and operations
Plants
Gaziantep, Turkey, Durabey-Istanbul, Turkey, Gray Court, SC
Processes
Spunbond, meltblown, spunlace, extrusion coated/laminated fabrics, Peva films, welded fabrics, converting
Major Markets
Bedding and furniture, medical, agriculture-landscape, luggage & shoe linings, filtration, oil sorbents/spill control, wipes, protective apparel, construction, hygiene, automotive, fabric softeners, laminating/coating substrates, packaging, vacuum cleaner dustbags
New plants in the U.S.—the company’s first foreign investment—and Turkey are among the recent headlines from Mogul Nonwovens. The Gaziantep, Turkey-based maker of spunbond, meltblown and spunlaced nonwovens reported a slight decline in sales for 2015 due to currency fluctuations and price reductions, mainly within its spunlace business.
“For sure our target is always to increase volume and turnover but there are factors beyond our control like exchange rates. So even though our sales reflect a decrease, there was not a sharp decrease with volume,” says CEO Serkan Gogus. “The reduction is due to pricing factors so we can’t say we are satisfied but we can’t complain too much.”
In August 2015, Mogul announced it would set up its first production outside of Turkey in Gray Court, SC. This $18 million investment will focus specifically on the production of spunlace nonwovens for medical, hygiene and wipes applications. The site’s 14,000-ton-per-year line is expected to start operation at the end of 2016 or early 2017.
“For parallel laid spunlace we mainly target wipes applications. We also see an increasing trend for hygiene applications while medical, automotive and coating substrates are some other applications,” Gogus says.
Mogul’s U.S. investment was precipitated by several reasons. “Since the beginning, the U.S. has always been among our major export markets and we have developed a good customer base and reputation in the marketplace. If you look at the global economy, you see uncertainty and problems in most parts of the world while the U.S. is sound and growing.”
The U.S. operation will be led by Darryl Fournier, a former executive with Suominen, Ahlstrom and Dexter, with the help of COO Beth Wolfe, Jonathan Layer, sales manager for the Americas Region, and Jerry Fan, business development director for Asia.
Back in Turkey, Mogul is in the process of installing two lines at a new site near Istanbul, Turkey. One of these lines is a crosslap line, which came onstream last month, while the other will offer a unique hybrid technology that produces fibrillated microfilament bico-hydroentangled spunbond nonwovens when it is complete this fall. Executives hope this hybrid microfilament line will open up new frontiers for nonwovens. The crosslap products will be sold under the Durell brand.
“As a player in spunlace area and a major player in technical applications we believe cross lap will be a good fit both to complement our wipes business and also open us up to new areas or applications with existing or new customers,” Gogus says. “The hybrid microfilament line is very unique and there are few of its kind in the world. We mainly target the apparel and upholstery segments, where nonwovens are not widely used so it will take time and efforts to establish such markets but we see it very challenging and exciting.”
New product development is also part of Mogul’s growth strategy. In April, the company launched a new product line comprising polyester-based thermoplastic polyurethane (TPU) fabrics under the Elastex brand of nonwovens. These products are designed to provide maximum elongation and maximum elastic recovery while offering high air permeability and resistance to abrasion, puncture, aging and ultraviolet light. Application areas include medical, pharmaceutical, hygiene, healthcare, sportswear and food packaging, beverage filters, automobile interior components, cable wraps, films and many others.
Another new product from the company is meltblown polybutylene terephthalate (PBT) in its nonwovens portfolio. Mogul’s PBT based production comes as an addition to its existing polypropylene (PP) meltblown products and is intended to increase Mogul’s offerings to the liquid and gas filtration markets.
Mogul’s heavier weight PBT meltblown fabrics can be pleated thus creating opportunities in gas and liquid filtration where high efficiency filtration is required. This PBT product is also a potential replacement for micro-glass filtration media. It is available in SM and SMS versions.
Gogus notes: “We are impressed with the results of our initial production and believe we will bring even more value addition to PBT fabric applications by way of our product’s unique characteristics.”
www.mogulsb.com
2015 Nonwovens Sales: $117 million
Key Personnel
Ekrem Kayali, chairman; C. Enver Kayali, president; Ayse Kayali, executive board member; Serkan Gogus, CEO; Murat G.Gökçe, general manager Durabey Istanbul plant, Darryl D.Fournier, president Mogul SC Nonwovens Corp; Ersin Kosker, director of projects and operations
Plants
Gaziantep, Turkey, Durabey-Istanbul, Turkey, Gray Court, SC
Processes
Spunbond, meltblown, spunlace, extrusion coated/laminated fabrics, Peva films, welded fabrics, converting
Major Markets
Bedding and furniture, medical, agriculture-landscape, luggage & shoe linings, filtration, oil sorbents/spill control, wipes, protective apparel, construction, hygiene, automotive, fabric softeners, laminating/coating substrates, packaging, vacuum cleaner dustbags
New plants in the U.S.—the company’s first foreign investment—and Turkey are among the recent headlines from Mogul Nonwovens. The Gaziantep, Turkey-based maker of spunbond, meltblown and spunlaced nonwovens reported a slight decline in sales for 2015 due to currency fluctuations and price reductions, mainly within its spunlace business.
“For sure our target is always to increase volume and turnover but there are factors beyond our control like exchange rates. So even though our sales reflect a decrease, there was not a sharp decrease with volume,” says CEO Serkan Gogus. “The reduction is due to pricing factors so we can’t say we are satisfied but we can’t complain too much.”
In August 2015, Mogul announced it would set up its first production outside of Turkey in Gray Court, SC. This $18 million investment will focus specifically on the production of spunlace nonwovens for medical, hygiene and wipes applications. The site’s 14,000-ton-per-year line is expected to start operation at the end of 2016 or early 2017.
“For parallel laid spunlace we mainly target wipes applications. We also see an increasing trend for hygiene applications while medical, automotive and coating substrates are some other applications,” Gogus says.
Mogul’s U.S. investment was precipitated by several reasons. “Since the beginning, the U.S. has always been among our major export markets and we have developed a good customer base and reputation in the marketplace. If you look at the global economy, you see uncertainty and problems in most parts of the world while the U.S. is sound and growing.”
The U.S. operation will be led by Darryl Fournier, a former executive with Suominen, Ahlstrom and Dexter, with the help of COO Beth Wolfe, Jonathan Layer, sales manager for the Americas Region, and Jerry Fan, business development director for Asia.
Back in Turkey, Mogul is in the process of installing two lines at a new site near Istanbul, Turkey. One of these lines is a crosslap line, which came onstream last month, while the other will offer a unique hybrid technology that produces fibrillated microfilament bico-hydroentangled spunbond nonwovens when it is complete this fall. Executives hope this hybrid microfilament line will open up new frontiers for nonwovens. The crosslap products will be sold under the Durell brand.
“As a player in spunlace area and a major player in technical applications we believe cross lap will be a good fit both to complement our wipes business and also open us up to new areas or applications with existing or new customers,” Gogus says. “The hybrid microfilament line is very unique and there are few of its kind in the world. We mainly target the apparel and upholstery segments, where nonwovens are not widely used so it will take time and efforts to establish such markets but we see it very challenging and exciting.”
New product development is also part of Mogul’s growth strategy. In April, the company launched a new product line comprising polyester-based thermoplastic polyurethane (TPU) fabrics under the Elastex brand of nonwovens. These products are designed to provide maximum elongation and maximum elastic recovery while offering high air permeability and resistance to abrasion, puncture, aging and ultraviolet light. Application areas include medical, pharmaceutical, hygiene, healthcare, sportswear and food packaging, beverage filters, automobile interior components, cable wraps, films and many others.
Another new product from the company is meltblown polybutylene terephthalate (PBT) in its nonwovens portfolio. Mogul’s PBT based production comes as an addition to its existing polypropylene (PP) meltblown products and is intended to increase Mogul’s offerings to the liquid and gas filtration markets.
Mogul’s heavier weight PBT meltblown fabrics can be pleated thus creating opportunities in gas and liquid filtration where high efficiency filtration is required. This PBT product is also a potential replacement for micro-glass filtration media. It is available in SM and SMS versions.
Gogus notes: “We are impressed with the results of our initial production and believe we will bring even more value addition to PBT fabric applications by way of our product’s unique characteristics.”
Gaziantep, Turkey
www.mogulsb.com
2016 Nonwovens Sales: $121 million
Key Personnel
Ekerem Kayali, chairman; C. Enver Kayali, president; Ayse Kayali, executive board member; Serkan Gogus, CEO; Darryl D. Fournier, president Mogul South Carolina Nonwovens Corp.; Ersin Kosker, director of projects and operations
Plants
Gaziantep, Turkey; Durabey-Istanbul, Turkey; Gray Court, SC
Processes
Spunbond, meltblown, spunlace, extrusion coated/laminated fabrics, PEVA films, welded fabrics, converting
Major Markets
Bedding and furniture, medical, agriculture-landscape, luggage and shoe linings, filtration, oil sorbents/spill control, wipes, protective apparel, construction, hygiene, automotive, fabric softeners, laminating/coating substrates, packaging, vacuum cleaner dustbags
Expansion into North America is the top story coming from Turkish nonwovens producer Mogul. In March, the company hosted a grand opening for its new spunlace facility in Grey Court, SC. The new site features a 15,000-ton spunlace line and is helping Mogul meet demand for its nonwoven products in the wipes, hygiene, filtration and automotives market. By expanding into the U.S. market, Mogul has positioned itself to better serve existing customers and capitalize on the growing need for high quality spunlace materials in North and South Americas as well as the Asian-Pacific region.
“Our customers have been delighted to see us invest in North America, as they are taking advantage of low lead times and an expanded supply chain assurance, among other things,” CEO Serkan Gogus says. “The facility is truly state-of-the-art, and our pharma-level micro lab and new carding technologies
www.mogulsb.com
2016 Nonwovens Sales: $121 million
Key Personnel
Ekerem Kayali, chairman; C. Enver Kayali, president; Ayse Kayali, executive board member; Serkan Gogus, CEO; Darryl D. Fournier, president Mogul South Carolina Nonwovens Corp.; Ersin Kosker, director of projects and operations
Plants
Gaziantep, Turkey; Durabey-Istanbul, Turkey; Gray Court, SC
Processes
Spunbond, meltblown, spunlace, extrusion coated/laminated fabrics, PEVA films, welded fabrics, converting
Major Markets
Bedding and furniture, medical, agriculture-landscape, luggage and shoe linings, filtration, oil sorbents/spill control, wipes, protective apparel, construction, hygiene, automotive, fabric softeners, laminating/coating substrates, packaging, vacuum cleaner dustbags
Expansion into North America is the top story coming from Turkish nonwovens producer Mogul. In March, the company hosted a grand opening for its new spunlace facility in Grey Court, SC. The new site features a 15,000-ton spunlace line and is helping Mogul meet demand for its nonwoven products in the wipes, hygiene, filtration and automotives market. By expanding into the U.S. market, Mogul has positioned itself to better serve existing customers and capitalize on the growing need for high quality spunlace materials in North and South Americas as well as the Asian-Pacific region.
“Our customers have been delighted to see us invest in North America, as they are taking advantage of low lead times and an expanded supply chain assurance, among other things,” CEO Serkan Gogus says. “The facility is truly state-of-the-art, and our pharma-level micro lab and new carding technologies
Gaziantep, Turkey
www.mogulsb.com
2017 Nonwovens Sales: $128 million
Key Personnel
Ekerem Kayali, chairman; Ayse Kayali, executive board member; Serkan Gogus, CEO; Darryl Fournier, president, Mogul South Carolina Nonwovens Corp.; Ersin Kosker, COO
Plants
Gaziantep, Turkey; Durabey-Istanbul, Turkey; Gray Court, SC
Processes
Spunbond (including bico and microfilament technologies), meltblown, spunlace, extrusion coated/laminated fabrics, PEVA films, welded fabrics, converting
Major Markets
Bedding and furniture, medical, agriculture-landscape, luggage and shoe linings, filtration, oil sorbents/spill control, wipes, protective apparel, construction, hygiene, automotives, fabric softeners, laminating/coatings substrates, packaging, vacuum cleaner dustings
Increasing contributions from new sites in South Carolina and Luleburgaz, Turkey, have helped offset negative currency rates at Mogul Nonwovens. The Gaziantep, Turkey-based nonwovens producer reports that its 2017 nonwovens sales increased from $121 million to $128 million. This upward trajectory has continued into 2018 thanks to better exchange rates between the U.S. and Turkey, raw material increases, growth at the company’s U.S. operation and increased interest in its Madaline and Durell product lines, according to CEO Serkan Gogus.
In March 2017, Mogul completed its first foreign operation in Grey Court, SC, where it began operating a state-of-the-art spunlace line. According to the company, the new line has started up well with minimal issues and its products are getting widespread acceptance in the marketplace. “In particular, the loft, web uniformity and hydroembossing capabilities have been well received,” says Gogus.
The main challenges Mogul has faced in South Carolina relate to labor tightness and polyester pricing/availability. However, the company has been able to find some great employees and expects to be fully staffed by year’s end. This has allowed Mogul to succeed in markets that require multiple functionalities such as high loft and softness, cleaning efficiency and strength or sustainability and absorbency. These include not only premium wipes and hygiene but also medical and technical applications.
Meanwhile in Turkey it has added a second site near Istanbul, which contains two lines, one based on crosslapping technology and a hybrid microfilament technology. The crosslapping technology makes new products featuring complex fibers, filaments and web formations as well as chemical treatments and printing applications. Mogul is marketing the material made on this line under the Durell brand, saying it complements existing spunlace fabric offerings and helps expand its role in the automotive, artificial leather, dry wipes, depilation pads, roofing, medical and hygiene markets.
The brand name for Mogul’s microfilament hybrid technology is Madaline. These materials can achieve fabric properties close to conventional textiles to target not only classic nonwovens end uses but also apparel, upholstery and home textile applications.
Gogus says that there is plenty of room for investment at both of the new plants. The Grey Court site is situated on 20 acres of land and has been described as just the start of Mogul’s North American investment strategy while a three-phase investment is intended for the Lulebrugaz site. However, Gogus says that there are no plans in place for investment at either site in the near term.
“For sure Mogul is managed with an entrepreneurial philosophy and we always look for ways to diversify and grow our business but for now we just finalized new investments. In mid and long term we will be looking at new investments,“ he adds.
www.mogulsb.com
2017 Nonwovens Sales: $128 million
Key Personnel
Ekerem Kayali, chairman; Ayse Kayali, executive board member; Serkan Gogus, CEO; Darryl Fournier, president, Mogul South Carolina Nonwovens Corp.; Ersin Kosker, COO
Plants
Gaziantep, Turkey; Durabey-Istanbul, Turkey; Gray Court, SC
Processes
Spunbond (including bico and microfilament technologies), meltblown, spunlace, extrusion coated/laminated fabrics, PEVA films, welded fabrics, converting
Major Markets
Bedding and furniture, medical, agriculture-landscape, luggage and shoe linings, filtration, oil sorbents/spill control, wipes, protective apparel, construction, hygiene, automotives, fabric softeners, laminating/coatings substrates, packaging, vacuum cleaner dustings
Increasing contributions from new sites in South Carolina and Luleburgaz, Turkey, have helped offset negative currency rates at Mogul Nonwovens. The Gaziantep, Turkey-based nonwovens producer reports that its 2017 nonwovens sales increased from $121 million to $128 million. This upward trajectory has continued into 2018 thanks to better exchange rates between the U.S. and Turkey, raw material increases, growth at the company’s U.S. operation and increased interest in its Madaline and Durell product lines, according to CEO Serkan Gogus.
In March 2017, Mogul completed its first foreign operation in Grey Court, SC, where it began operating a state-of-the-art spunlace line. According to the company, the new line has started up well with minimal issues and its products are getting widespread acceptance in the marketplace. “In particular, the loft, web uniformity and hydroembossing capabilities have been well received,” says Gogus.
The main challenges Mogul has faced in South Carolina relate to labor tightness and polyester pricing/availability. However, the company has been able to find some great employees and expects to be fully staffed by year’s end. This has allowed Mogul to succeed in markets that require multiple functionalities such as high loft and softness, cleaning efficiency and strength or sustainability and absorbency. These include not only premium wipes and hygiene but also medical and technical applications.
Meanwhile in Turkey it has added a second site near Istanbul, which contains two lines, one based on crosslapping technology and a hybrid microfilament technology. The crosslapping technology makes new products featuring complex fibers, filaments and web formations as well as chemical treatments and printing applications. Mogul is marketing the material made on this line under the Durell brand, saying it complements existing spunlace fabric offerings and helps expand its role in the automotive, artificial leather, dry wipes, depilation pads, roofing, medical and hygiene markets.
The brand name for Mogul’s microfilament hybrid technology is Madaline. These materials can achieve fabric properties close to conventional textiles to target not only classic nonwovens end uses but also apparel, upholstery and home textile applications.
Gogus says that there is plenty of room for investment at both of the new plants. The Grey Court site is situated on 20 acres of land and has been described as just the start of Mogul’s North American investment strategy while a three-phase investment is intended for the Lulebrugaz site. However, Gogus says that there are no plans in place for investment at either site in the near term.
“For sure Mogul is managed with an entrepreneurial philosophy and we always look for ways to diversify and grow our business but for now we just finalized new investments. In mid and long term we will be looking at new investments,“ he adds.
Gaziantep, Turkey
www.mogulsb.com
2018 Nonwovens Sales: $133 million
Key Personnel
Ekerem Kayali, chairman; Ayse Kayali, executive board member; Serkan Gogus, CEO; Darryl Fournier, president, Mogul South Carolina Nonwovens Corp.; Ersin Kosker, COO
Plants
Gaziantep, Turkey; Durabey-Istanbul, Turkey; Gray Court, SC
Processes
Spunbond (including bico and microfilament technologies), meltblown, spunlace, extrusion coated/laminated fabrics, PEVA films, welded fabrics, converting
Major Markets
Bedding and furniture, medical, agriculture-landscape, luggage and shoe linings, filtration, oil sorbents/spill control, wipes, protective apparel, construction, hygiene, automotives, fabric softeners, laminating/coatings substrates, packaging, vacuum cleaner dustings
Benefitting from recent investments including new sites in Luleburgaz, Turkey, and Grey Court, SC, Mogul’s nonwovens sales increased to $133 million in 2018, however 2019 sales will be negatively impacted by the sale of Mogul’s U.S. operation which was finalized in January.
Mogul sold its spunlace operation in Grey Court to Fibertex Nonwovens earlier this year, just 18 months after it began operation. The facility contains one 3.2 meter high-seed parallel laid spunlace line with 15,000 tons of capacity.
Divesting the U.S. operation made good financial sense for the company, according to CEO Serkan Gogus.
“Besides the negative economic climate in Turkey, significant changes in government policies in energy sector made such investments unfeasible,” he says. “Also it turned out that payback time of U.S. investment seems to be longer than anticipated which we had to finance in the short term so we decided to sell U.S. investment and use it to strengthen our financial status and reduce overall indebtedness. We also decided to quit the energy business and focus on core strengths.”
One area of intense interest is Madaline, Mogul’s microfilament hybrid technology that can achieve fabric properties close to conventional textiles to target not only classic nonwoven end uses, but also apparel, upholstery and home textile applications.
“Madaline is a unique technology and fabric,” Gogus says. “It bridges the gap between conventional textiles and nonwovens. We especially target apparel and home textile applications and we have ongoing development efforts with global brands.”
Mogul makes Madaline at its new site in Luleburgaz, Turkey. This site also houses a line featuring crosslapping technology to make products featuring complex fibers, filaments and web formations as well as chemical treatments and printing applications. Mogul is marketing the materials made on this line under the Durell brand, saying it complements existing spunlace fabric offerings and helps expand its role in the automotive, artificial leather, dry wipes, depilation pads, roofing, medical and hygiene applications.
For the short term, Mogul will focus on these new investments and the technologies they yield, hoping to grow in existing markets and opening up new business opportunities.
“In next couple of years we plan to digest new investments and strengthen our positions,” Gogus says. “For sure we continuously think and work on new projects but there is no plan for expansion in the short term.”
In short, the company plans to renovate and debottleneck existing lines to ensure the capacity is fully utilized and increase sales. Once that is done, the company will resume looking at new investment ideas to diversify its product range and complement existing products.
www.mogulsb.com
2018 Nonwovens Sales: $133 million
Key Personnel
Ekerem Kayali, chairman; Ayse Kayali, executive board member; Serkan Gogus, CEO; Darryl Fournier, president, Mogul South Carolina Nonwovens Corp.; Ersin Kosker, COO
Plants
Gaziantep, Turkey; Durabey-Istanbul, Turkey; Gray Court, SC
Processes
Spunbond (including bico and microfilament technologies), meltblown, spunlace, extrusion coated/laminated fabrics, PEVA films, welded fabrics, converting
Major Markets
Bedding and furniture, medical, agriculture-landscape, luggage and shoe linings, filtration, oil sorbents/spill control, wipes, protective apparel, construction, hygiene, automotives, fabric softeners, laminating/coatings substrates, packaging, vacuum cleaner dustings
Benefitting from recent investments including new sites in Luleburgaz, Turkey, and Grey Court, SC, Mogul’s nonwovens sales increased to $133 million in 2018, however 2019 sales will be negatively impacted by the sale of Mogul’s U.S. operation which was finalized in January.
Mogul sold its spunlace operation in Grey Court to Fibertex Nonwovens earlier this year, just 18 months after it began operation. The facility contains one 3.2 meter high-seed parallel laid spunlace line with 15,000 tons of capacity.
Divesting the U.S. operation made good financial sense for the company, according to CEO Serkan Gogus.
“Besides the negative economic climate in Turkey, significant changes in government policies in energy sector made such investments unfeasible,” he says. “Also it turned out that payback time of U.S. investment seems to be longer than anticipated which we had to finance in the short term so we decided to sell U.S. investment and use it to strengthen our financial status and reduce overall indebtedness. We also decided to quit the energy business and focus on core strengths.”
One area of intense interest is Madaline, Mogul’s microfilament hybrid technology that can achieve fabric properties close to conventional textiles to target not only classic nonwoven end uses, but also apparel, upholstery and home textile applications.
“Madaline is a unique technology and fabric,” Gogus says. “It bridges the gap between conventional textiles and nonwovens. We especially target apparel and home textile applications and we have ongoing development efforts with global brands.”
Mogul makes Madaline at its new site in Luleburgaz, Turkey. This site also houses a line featuring crosslapping technology to make products featuring complex fibers, filaments and web formations as well as chemical treatments and printing applications. Mogul is marketing the materials made on this line under the Durell brand, saying it complements existing spunlace fabric offerings and helps expand its role in the automotive, artificial leather, dry wipes, depilation pads, roofing, medical and hygiene applications.
For the short term, Mogul will focus on these new investments and the technologies they yield, hoping to grow in existing markets and opening up new business opportunities.
“In next couple of years we plan to digest new investments and strengthen our positions,” Gogus says. “For sure we continuously think and work on new projects but there is no plan for expansion in the short term.”
In short, the company plans to renovate and debottleneck existing lines to ensure the capacity is fully utilized and increase sales. Once that is done, the company will resume looking at new investment ideas to diversify its product range and complement existing products.
Gaziantep, Turkey
www.mogulsb.com
2019 Nonwovens Sales: $133 million
Key Personnel
Ekerem Kayali, chairman; Ayse Kayali, executive board member; Serkan Gogus, CEO; Ersin Kosker, COO
Plants
Gaziantep, Turkey; Durabey-Istanbul, Turkey; Gray Court, SC
Processes
Spunbond (including bico and microfilament technologies), meltblown, spunlace, extrusion coated/laminated fabrics, PEVA films, welded fabrics, converting
Major Markets
Bedding and furniture, medical, agriculture-landscape, luggage and shoe linings, filtration, oil sorbents/spill control, wipes, protective apparel, construction, hygiene, automotives, fabric softeners, laminating/coatings substrates, packaging, vacuum cleaner dustings
The effects of new investments including a bicomponent line in Gaziantep and a new facility in Luleburgaz, Turkey, helped drive sales to $133 million for Mogul. These additions were able to offset the impact of Mogul’s sale of its U.S. facility, in Grey Court, SC, to Fibertex Nonwovens, particularly since that line was not running at full capacity. Mogul had added a 3.2-meter, 15,000-ton high-speed parallel laid spunlace line in May 2017 and sold it in January 2019.
“The sale has allowed us to focus on our new site in Luleburgaz and focus on new products like Madaline and Durell,” says commercial director Serkan Gogus. “It has given us more time to focus on developments.”
Madaline is Mogul’s microfilament hybrid technology that can achieve fabric properties close to conventional textiles to target not only classic nonwoven uses but also apparel, upholstery and home textile applications by bridging the gap between conventional textiles and nonwovens.
This spring, Mogul announced it was using Madaline to make reusable and washable cloth face masks
The Madaline microfilament cloth face mask offers up to 90% bacterial filtration efficiency and up to 98% particle filtration efficiency while being skin and allergy friendly, breathable, soft and comfortable
Mogul makes Madaline at its new site in Luleburgaz, Turkey, which was added in 2017. This site also houses a line featuring crosslapping technology to make products featuring complex fibers, filaments and web formations as well as chemical treatments and printing applications. Mogul is marketing the materials made on this line under the Durell brand, saying it complements existing spunlace fabric offerings and helps expand its role in the automotive, artificial leather, dry wipes, depilation pads, roofing, medical and hygiene applications.
In the next couple of years, Gogus says he expects to see additional new applications for both technologies as the company looks toward areas currently targeted by traditional textiles.
Meanwhile, Mogul has focused on debottlenecking projects on its existing lines, particularly in spunbond, meltblown and spunlace technologies where demand has spiked due to the coronavirus.
“We have seen a significant increase with demand for PP spunbond, meltblown and spunlace fabrics,” Gogus says. “For first time in 23 years I have observed a seller’s market in these areas, but there have been some declines in durable applications like automotives and filtration.”
www.mogulsb.com
2019 Nonwovens Sales: $133 million
Key Personnel
Ekerem Kayali, chairman; Ayse Kayali, executive board member; Serkan Gogus, CEO; Ersin Kosker, COO
Plants
Gaziantep, Turkey; Durabey-Istanbul, Turkey; Gray Court, SC
Processes
Spunbond (including bico and microfilament technologies), meltblown, spunlace, extrusion coated/laminated fabrics, PEVA films, welded fabrics, converting
Major Markets
Bedding and furniture, medical, agriculture-landscape, luggage and shoe linings, filtration, oil sorbents/spill control, wipes, protective apparel, construction, hygiene, automotives, fabric softeners, laminating/coatings substrates, packaging, vacuum cleaner dustings
The effects of new investments including a bicomponent line in Gaziantep and a new facility in Luleburgaz, Turkey, helped drive sales to $133 million for Mogul. These additions were able to offset the impact of Mogul’s sale of its U.S. facility, in Grey Court, SC, to Fibertex Nonwovens, particularly since that line was not running at full capacity. Mogul had added a 3.2-meter, 15,000-ton high-speed parallel laid spunlace line in May 2017 and sold it in January 2019.
“The sale has allowed us to focus on our new site in Luleburgaz and focus on new products like Madaline and Durell,” says commercial director Serkan Gogus. “It has given us more time to focus on developments.”
Madaline is Mogul’s microfilament hybrid technology that can achieve fabric properties close to conventional textiles to target not only classic nonwoven uses but also apparel, upholstery and home textile applications by bridging the gap between conventional textiles and nonwovens.
This spring, Mogul announced it was using Madaline to make reusable and washable cloth face masks
The Madaline microfilament cloth face mask offers up to 90% bacterial filtration efficiency and up to 98% particle filtration efficiency while being skin and allergy friendly, breathable, soft and comfortable
Mogul makes Madaline at its new site in Luleburgaz, Turkey, which was added in 2017. This site also houses a line featuring crosslapping technology to make products featuring complex fibers, filaments and web formations as well as chemical treatments and printing applications. Mogul is marketing the materials made on this line under the Durell brand, saying it complements existing spunlace fabric offerings and helps expand its role in the automotive, artificial leather, dry wipes, depilation pads, roofing, medical and hygiene applications.
In the next couple of years, Gogus says he expects to see additional new applications for both technologies as the company looks toward areas currently targeted by traditional textiles.
Meanwhile, Mogul has focused on debottlenecking projects on its existing lines, particularly in spunbond, meltblown and spunlace technologies where demand has spiked due to the coronavirus.
“We have seen a significant increase with demand for PP spunbond, meltblown and spunlace fabrics,” Gogus says. “For first time in 23 years I have observed a seller’s market in these areas, but there have been some declines in durable applications like automotives and filtration.”
Gaziantep, Turkey
www.mogulsb.com
2020 Nonwovens Sales: $152 million
Key Personnel
Ekrem Kayali, chairman; Ayse Kayali, executive board member; Serkan Gogus, CEO; Ersin Kosker, COO
Plants
Gaziantep, Turkey; Durabey-Istanbul, Turkey
Processes
Spunbond (including bico and microfilament technologies), meltblown, spunlace, extrusion coated/laminated fabrics, welded fabrics, converting
Major Markets
Bedding and furniture, medical, agriculture-landscape, luggage and shoe linings, filtration, oil sorbents/spill control, wipes, protective apparel, construction, hygiene, automotives, fabric softeners, laminating/coatings substrates, packaging, vacuum cleaner dustings
Mogul Nonwovens’ sales reached $152 million in 2020 due to high capacity utilization in the spunbond, spunlace and meltblown areas as well as increased pricing caused by high pandemic-related demand. The company operates two plants in Turkey offering a variety of nonwovens technologies in a number a of markets.
“We have seen significant demand for polypropylene meltblown and spunlace due to demand for masks and hygiene products during the coronavirus pandemic,” says CEO Serkan Gogus. “We did observe a decline in demand for some durable applications and the government banned exports of meltblown obliged us to meet the spunbond demands of local producers. We tried to meet local demands with available capacity while also exporting to customers as much as we can. This means using some of the polypropylene intended for durable applications into new areas.”
In November 2020, Mogul announced it would add two meltblown lines to its manufacturing footprint. One line is already up and running and the second is scheduled to start up in the fourth quarter of this year. They are both 160 centimeters wide and capable of making fabrics in the 15-100 gsm range. Both lines feature electrostatic charged capabilities capable for N95 and higher efficiency masks as well as high efficiency filtration applications and other industrial applications.
The new lines will represent Mogul’s fifth and sixth meltblown lines. The company has been involved with this technology since 2000 but its previous lines were designed to make spill control products or sorbents.
“We observed increases in demand for high efficiency masks and filtration products, and we decided to invest in these lines,” Gogus says. “We do foresee overcapacity in all aspects of meltblown—as well as polypropylene spunbond and spunlace nonwovens—due to new investments, but as usual we will differentiate our products, target niche areas and try to make a portfolio for customers with diversified range of products.”
In recent years, Mogul has made a number of new investments intended to grow and diversify its product line as well as solidify its market position. These include a bicomponent line in Gaziantep and a new facility in Luleburgaz, Turkey, as well as a U.S. facility in Grey Court, SC, which was sold to Fibertex Nonwovens in January 2019.
The Luleburgaz site is where Mogul makes Madaline, its microfilament hybrid technology that can achieve fabric properties close to conventional textiles to target not only classic nonwoven uses but also apparel, upholstery and home textile applications by bridging the gap between conventional textiles and nonwovens.
The site, which was added in 2017, also houses a line featuring crosslapping technology to make products featuring complex fibers, filaments and web formations as well as chemical treatments and printing applications. Mogul is marketing the materials made on this line under the Durell brand, saying it complements existing spunlace fabric offerings and helps expand its role in the automotive, artificial leather, dry wipes, depilation pads, roofing, medical and hygiene applications.
www.mogulsb.com
2020 Nonwovens Sales: $152 million
Key Personnel
Ekrem Kayali, chairman; Ayse Kayali, executive board member; Serkan Gogus, CEO; Ersin Kosker, COO
Plants
Gaziantep, Turkey; Durabey-Istanbul, Turkey
Processes
Spunbond (including bico and microfilament technologies), meltblown, spunlace, extrusion coated/laminated fabrics, welded fabrics, converting
Major Markets
Bedding and furniture, medical, agriculture-landscape, luggage and shoe linings, filtration, oil sorbents/spill control, wipes, protective apparel, construction, hygiene, automotives, fabric softeners, laminating/coatings substrates, packaging, vacuum cleaner dustings
Mogul Nonwovens’ sales reached $152 million in 2020 due to high capacity utilization in the spunbond, spunlace and meltblown areas as well as increased pricing caused by high pandemic-related demand. The company operates two plants in Turkey offering a variety of nonwovens technologies in a number a of markets.
“We have seen significant demand for polypropylene meltblown and spunlace due to demand for masks and hygiene products during the coronavirus pandemic,” says CEO Serkan Gogus. “We did observe a decline in demand for some durable applications and the government banned exports of meltblown obliged us to meet the spunbond demands of local producers. We tried to meet local demands with available capacity while also exporting to customers as much as we can. This means using some of the polypropylene intended for durable applications into new areas.”
In November 2020, Mogul announced it would add two meltblown lines to its manufacturing footprint. One line is already up and running and the second is scheduled to start up in the fourth quarter of this year. They are both 160 centimeters wide and capable of making fabrics in the 15-100 gsm range. Both lines feature electrostatic charged capabilities capable for N95 and higher efficiency masks as well as high efficiency filtration applications and other industrial applications.
The new lines will represent Mogul’s fifth and sixth meltblown lines. The company has been involved with this technology since 2000 but its previous lines were designed to make spill control products or sorbents.
“We observed increases in demand for high efficiency masks and filtration products, and we decided to invest in these lines,” Gogus says. “We do foresee overcapacity in all aspects of meltblown—as well as polypropylene spunbond and spunlace nonwovens—due to new investments, but as usual we will differentiate our products, target niche areas and try to make a portfolio for customers with diversified range of products.”
In recent years, Mogul has made a number of new investments intended to grow and diversify its product line as well as solidify its market position. These include a bicomponent line in Gaziantep and a new facility in Luleburgaz, Turkey, as well as a U.S. facility in Grey Court, SC, which was sold to Fibertex Nonwovens in January 2019.
The Luleburgaz site is where Mogul makes Madaline, its microfilament hybrid technology that can achieve fabric properties close to conventional textiles to target not only classic nonwoven uses but also apparel, upholstery and home textile applications by bridging the gap between conventional textiles and nonwovens.
The site, which was added in 2017, also houses a line featuring crosslapping technology to make products featuring complex fibers, filaments and web formations as well as chemical treatments and printing applications. Mogul is marketing the materials made on this line under the Durell brand, saying it complements existing spunlace fabric offerings and helps expand its role in the automotive, artificial leather, dry wipes, depilation pads, roofing, medical and hygiene applications.
Gaziantep, Turkey
www.mogulsb.com
2021 Nonwovens Sales: $148 million
Key Personnel
Ekrem Kayali, chairman; Ayse Kayali, executive board member; Serkan Gogus, CEO; Ersin Kosker, COO
Plants
Gaziantep, Turkey; Durabey-Istanbul, Turkey
Processes
Spunbond (including bico and microfilament technologies), meltblown, spunlace, extrusion coated/laminated fabrics, welded fabrics, converting
According to Serkan Gogus, CEO, sales at Mogul declined in areas like face masks and wipes between 2020-2021, while increases were felt in household and durable applications. The result was overall nonwovens sales for the Gaziantep, Turkey-based nonwovens producer decreasing slightly to $144 million. Moving on to 2022, significant increases in raw material prices, high freight costs and supply chain disruption has impacted Mogul’s performance in high-competition areas like polypropylene-based spunbond and spunlaced where it is difficult to pass on price increases, particularly in North America and to some degree in Europe.
“Frankly, we don’t see a bright scenario for 2022,” Gogus says. “With the hope of ending war in Ukraine we might see some relief with energy costs.”
As prices have increased, it has been difficult for Mogul to pass them through to its customers due to high competition and increased capacities especially in spunbond, meltblown and spunlace nonwovens as well as the devaluation of the Turkish currency.
“There is an overcapacity for polypropylene spunbond and spunlace nonwovens especially in Turkey due to significant investments in last couple of years,” Gogus adds. “The capacity increases were somehow working in times of strong demand during Covid but as things begin to return normal this is becoming more challenging.”
During the coronavirus, Mogul decided to expand its meltblown output with the addition of two lines, which came onstream in 2021. Both lines are 160 centimeters wide and capable of making fabrics in the 15-100 gsm range and feature electrostatic charged capabilities capable for N95 and higher efficiency masks as well as high efficiency filtration applications and other industrial applications.
While these investments largely targeted respirators, face masks and other healthcare related applications during the height of the coronavirus pandemic, demand in these areas has waned in recent months, allowing manufacturers to examine other areas for meltblown including spill control, filters and wipes.
In recent years, Mogul has made a number of new investments intended to grow and diversify its product line as well as solidify its market position. These include a bicomponent line in Gaziantep and a new facility in Luleburgaz, Turkey.
The Luleburgaz site is where Mogul makes Madaline, its microfilament hybrid technology that can achieve fabric properties close to conventional textiles to target not only classic nonwoven uses but also apparel, upholstery and home textile applications by bridging the gap between conventional textiles and nonwovens. The company has recently expanded the Luleburgaz site to make room for future investments however, no decisions have been finalized.
Within its Madaline range, the company recently introduced a filter media made from PET and CoPET on the same platform. The material targets filtration applications especially in heavier ranges up to 250 gsm.
Mogul is also working using Madaline to development a new product featuring extra treatments for upholstery and home textile applications.
Within its Durell bicomponent line, Mogul is developing some unique grades made from UHMWPE. The result is a product with unique ballistic properties and puncture resistance which can be used for military applications and also for upholstery and protective footwear, climbing gear, cycling wear, anti-vandal products and protectors for a wide range of industries.
Another high tech product, Metatex, is a crosslap spunlaced nonwovens made from meta and para-aramid and blends to create a range of high-grade fabrics that answer the market’s needs for a lightweight material for thermal clothing. These fabrics can be used in firefighter protective clothing and rubber reinforcements, automotive hoses and filtration systems where it can provides a longer lifetime.
Mogul is increasing its range of sustainable products inline with increasing demand for natural, renewable biobased and circular recycled products. In addition to products using viscose, lyocell, cotton, bamboo and PLA, Mogul is introducing two new products in its range including a 100% bio-based polyester or blended products between 30 gsm and 200 gsm in parallel and cross production lines.
For Mogul's 2020 top company profile, click here.
www.mogulsb.com
2021 Nonwovens Sales: $148 million
Key Personnel
Ekrem Kayali, chairman; Ayse Kayali, executive board member; Serkan Gogus, CEO; Ersin Kosker, COO
Plants
Gaziantep, Turkey; Durabey-Istanbul, Turkey
Processes
Spunbond (including bico and microfilament technologies), meltblown, spunlace, extrusion coated/laminated fabrics, welded fabrics, converting
According to Serkan Gogus, CEO, sales at Mogul declined in areas like face masks and wipes between 2020-2021, while increases were felt in household and durable applications. The result was overall nonwovens sales for the Gaziantep, Turkey-based nonwovens producer decreasing slightly to $144 million. Moving on to 2022, significant increases in raw material prices, high freight costs and supply chain disruption has impacted Mogul’s performance in high-competition areas like polypropylene-based spunbond and spunlaced where it is difficult to pass on price increases, particularly in North America and to some degree in Europe.
“Frankly, we don’t see a bright scenario for 2022,” Gogus says. “With the hope of ending war in Ukraine we might see some relief with energy costs.”
As prices have increased, it has been difficult for Mogul to pass them through to its customers due to high competition and increased capacities especially in spunbond, meltblown and spunlace nonwovens as well as the devaluation of the Turkish currency.
“There is an overcapacity for polypropylene spunbond and spunlace nonwovens especially in Turkey due to significant investments in last couple of years,” Gogus adds. “The capacity increases were somehow working in times of strong demand during Covid but as things begin to return normal this is becoming more challenging.”
During the coronavirus, Mogul decided to expand its meltblown output with the addition of two lines, which came onstream in 2021. Both lines are 160 centimeters wide and capable of making fabrics in the 15-100 gsm range and feature electrostatic charged capabilities capable for N95 and higher efficiency masks as well as high efficiency filtration applications and other industrial applications.
While these investments largely targeted respirators, face masks and other healthcare related applications during the height of the coronavirus pandemic, demand in these areas has waned in recent months, allowing manufacturers to examine other areas for meltblown including spill control, filters and wipes.
In recent years, Mogul has made a number of new investments intended to grow and diversify its product line as well as solidify its market position. These include a bicomponent line in Gaziantep and a new facility in Luleburgaz, Turkey.
The Luleburgaz site is where Mogul makes Madaline, its microfilament hybrid technology that can achieve fabric properties close to conventional textiles to target not only classic nonwoven uses but also apparel, upholstery and home textile applications by bridging the gap between conventional textiles and nonwovens. The company has recently expanded the Luleburgaz site to make room for future investments however, no decisions have been finalized.
Within its Madaline range, the company recently introduced a filter media made from PET and CoPET on the same platform. The material targets filtration applications especially in heavier ranges up to 250 gsm.
Mogul is also working using Madaline to development a new product featuring extra treatments for upholstery and home textile applications.
Within its Durell bicomponent line, Mogul is developing some unique grades made from UHMWPE. The result is a product with unique ballistic properties and puncture resistance which can be used for military applications and also for upholstery and protective footwear, climbing gear, cycling wear, anti-vandal products and protectors for a wide range of industries.
Another high tech product, Metatex, is a crosslap spunlaced nonwovens made from meta and para-aramid and blends to create a range of high-grade fabrics that answer the market’s needs for a lightweight material for thermal clothing. These fabrics can be used in firefighter protective clothing and rubber reinforcements, automotive hoses and filtration systems where it can provides a longer lifetime.
Mogul is increasing its range of sustainable products inline with increasing demand for natural, renewable biobased and circular recycled products. In addition to products using viscose, lyocell, cotton, bamboo and PLA, Mogul is introducing two new products in its range including a 100% bio-based polyester or blended products between 30 gsm and 200 gsm in parallel and cross production lines.
For Mogul's 2020 top company profile, click here.
Gaziantep, Turkey
www.mogulsb.com
2022 Nonwovens Sales: $141 million
Key Personnel
Ekrem Kayali, chairman; Ayse Kayali, executive board member; Serkan Gogus, CEO; Ersin Kosker, COO
Plants
Gaziantep, Turkey; Durabey-Istanbul, Turkey
Processes
Spunbond (including bico and microfilament technologies), meltblown, spunlace, extrusion coated/laminated fabrics, welded fabrics, converting
Sales decreased to $141 million in 2022 at Mogul Nonwovens due to increased competition, price reductions and reduction in sales following a slowdown in pandemic-related demand.
“Declining sales after the pandemic and significant investments made during that period—especially effecting polypropylene spunbond, meltblown and spunlace—has impacted us,” says CEO Serkan Gogus.
In Turkey, spunlace capacity more than doubled in recent years amidst rising freight rates. This has made doing business globally more competitive. Even though post pandemic demand is still higher than it was before, increased capacity as well as the return of Chinese-made imports in many markets, have kept prices low in many markets.
Meanwhile, meltblown continues to be an important market for Mogul. One of the largest producers of the technology globally and potentially the largest in Europe, Mogul operates seven lines, three of which were made during and after the pandemic to produce mask material. Additionally, Mogul’s filtration, spill control and wipes businesses are all performing well and the company is working on the development of new filtration grades.
In addition to these new meltblown lines, Mogul has also added a polyester bicomponent line, which is scheduled to start at the end of the year. As it embarks on these significant investments, Mogul continues to focus on developments within its many high performance product ranges.
Within its Madaline business, a microfilament technology produced at Mogul’s Luleburgaz, Turkey site, the introduction of Madaline Ultraleather, is targeting premium clothing/shoes, automotive and upholstery applications. Meanwhile, Mogul’s Durell, a bicomponent material, now includes some unique grades made from UHMWPE. The result is a product with unique ballistic properties and puncture resistance which can be used for military applications and also for upholstery and protective footwear, climbing gear, cycling wear, anti-vandal products and protectors for a wide range of industries. Recently, the company has expanded its offerings in this market with the introduction of new sustainable grades.
Additional new launches include Repreve nonwovens featuring recycled and other sustainably sourced raw materials like bio-PET, bamboo, linen and hemp.
www.mogulsb.com
2022 Nonwovens Sales: $141 million
Key Personnel
Ekrem Kayali, chairman; Ayse Kayali, executive board member; Serkan Gogus, CEO; Ersin Kosker, COO
Plants
Gaziantep, Turkey; Durabey-Istanbul, Turkey
Processes
Spunbond (including bico and microfilament technologies), meltblown, spunlace, extrusion coated/laminated fabrics, welded fabrics, converting
Sales decreased to $141 million in 2022 at Mogul Nonwovens due to increased competition, price reductions and reduction in sales following a slowdown in pandemic-related demand.
“Declining sales after the pandemic and significant investments made during that period—especially effecting polypropylene spunbond, meltblown and spunlace—has impacted us,” says CEO Serkan Gogus.
In Turkey, spunlace capacity more than doubled in recent years amidst rising freight rates. This has made doing business globally more competitive. Even though post pandemic demand is still higher than it was before, increased capacity as well as the return of Chinese-made imports in many markets, have kept prices low in many markets.
Meanwhile, meltblown continues to be an important market for Mogul. One of the largest producers of the technology globally and potentially the largest in Europe, Mogul operates seven lines, three of which were made during and after the pandemic to produce mask material. Additionally, Mogul’s filtration, spill control and wipes businesses are all performing well and the company is working on the development of new filtration grades.
In addition to these new meltblown lines, Mogul has also added a polyester bicomponent line, which is scheduled to start at the end of the year. As it embarks on these significant investments, Mogul continues to focus on developments within its many high performance product ranges.
Within its Madaline business, a microfilament technology produced at Mogul’s Luleburgaz, Turkey site, the introduction of Madaline Ultraleather, is targeting premium clothing/shoes, automotive and upholstery applications. Meanwhile, Mogul’s Durell, a bicomponent material, now includes some unique grades made from UHMWPE. The result is a product with unique ballistic properties and puncture resistance which can be used for military applications and also for upholstery and protective footwear, climbing gear, cycling wear, anti-vandal products and protectors for a wide range of industries. Recently, the company has expanded its offerings in this market with the introduction of new sustainable grades.
Additional new launches include Repreve nonwovens featuring recycled and other sustainably sourced raw materials like bio-PET, bamboo, linen and hemp.
Gaziantep, Turkey
www.mogulsb.com
2023 Nonwovens Sales: $113 million
Key Personnel
Ekrem Kayali, chairman; Ayse Kayali, executive board member; Serkan Gogus, CEO; Ersin Kosker, COO
Plants
Gaziantep, Turkey; Durabey-Istanbul, Turkey
Processes
Spunbond (including bico and microfilament technologies), meltblown, spunlace, extrusion coated/laminated fabrics, welded fabrics, converting
The combined effects of declining demand and excess capacity, particularly in polypropylene spunbond and spunlaced nonwovens, contributed to decreased sales for Mogul Nonwovens. The company reported sales of $113 million in 2023, compared to $141 million in 2022.
“Capacity in Turkey more than doubled, which created an overcapacity which created a price war and profit erosion,” says CEO Serkan Gogus. “Also, high inflation has negatively affected results.”
The biggest challenges have been felt in the spunlace market, where Mogul offers substrates based on a range of technologies and raw materials, all made in Turkey, because of aggressive pricing conditions in the wipes market, the largest market for spunlace. “Price levels are low and line capacities are high and we see the biggest problem in Turkey as major investments are here,” Gogus adds.
In defense of these conditions, Mogul has focused on value-added and niche products as well as a diversified product range. The company offers seven technology platforms that create a variety of markets and customers and allows Mogul to focus more on value than volume and offer value-added products. Much of these developments are made at Mogul’s government-recognized research and development center, located in Turkey, in collaboration with suppliers, universities and customers.
Recent technological developments include a specialty grade of its Madaline microfilament nonwovens, called Madaline Ultraleather, which is a leather-like material offering a fabric feel. This material continues to target clothing and home textile applications. Additionally, Mogul’s Durell, a bicomponent material, now includes some unique grades made from UHMWPE. The result is a product with unique ballistic properties and puncture resistance that can be used for military applications and also for upholstery and protective footwear, climbing gear, cycling wear, anti-vandal products and protectors for a wide range of industries. Recently, the company has expanded its offerings in this market with the introduction of new sustainable grades.
Additionally, Mogul has expanded sustainable product options with the launch of Repreve nonwovens featuring recycled and other greener raw materials like bio-PET, bamboo, linen and hemp.
“We are seeing a demand from the market for sustainable products and I believe with legal regulations this process will be accelerated,” Gogus says. “We are working on all product groups to develop sustainable product offerings and transform technologies to serve this target. We started working with a consulting firm for calculating and reporting our carbon and water footprint. This will also help us to understand points to develop and transform the business.”
www.mogulsb.com
2023 Nonwovens Sales: $113 million
Key Personnel
Ekrem Kayali, chairman; Ayse Kayali, executive board member; Serkan Gogus, CEO; Ersin Kosker, COO
Plants
Gaziantep, Turkey; Durabey-Istanbul, Turkey
Processes
Spunbond (including bico and microfilament technologies), meltblown, spunlace, extrusion coated/laminated fabrics, welded fabrics, converting
The combined effects of declining demand and excess capacity, particularly in polypropylene spunbond and spunlaced nonwovens, contributed to decreased sales for Mogul Nonwovens. The company reported sales of $113 million in 2023, compared to $141 million in 2022.
“Capacity in Turkey more than doubled, which created an overcapacity which created a price war and profit erosion,” says CEO Serkan Gogus. “Also, high inflation has negatively affected results.”
The biggest challenges have been felt in the spunlace market, where Mogul offers substrates based on a range of technologies and raw materials, all made in Turkey, because of aggressive pricing conditions in the wipes market, the largest market for spunlace. “Price levels are low and line capacities are high and we see the biggest problem in Turkey as major investments are here,” Gogus adds.
In defense of these conditions, Mogul has focused on value-added and niche products as well as a diversified product range. The company offers seven technology platforms that create a variety of markets and customers and allows Mogul to focus more on value than volume and offer value-added products. Much of these developments are made at Mogul’s government-recognized research and development center, located in Turkey, in collaboration with suppliers, universities and customers.
Recent technological developments include a specialty grade of its Madaline microfilament nonwovens, called Madaline Ultraleather, which is a leather-like material offering a fabric feel. This material continues to target clothing and home textile applications. Additionally, Mogul’s Durell, a bicomponent material, now includes some unique grades made from UHMWPE. The result is a product with unique ballistic properties and puncture resistance that can be used for military applications and also for upholstery and protective footwear, climbing gear, cycling wear, anti-vandal products and protectors for a wide range of industries. Recently, the company has expanded its offerings in this market with the introduction of new sustainable grades.
Additionally, Mogul has expanded sustainable product options with the launch of Repreve nonwovens featuring recycled and other greener raw materials like bio-PET, bamboo, linen and hemp.
“We are seeing a demand from the market for sustainable products and I believe with legal regulations this process will be accelerated,” Gogus says. “We are working on all product groups to develop sustainable product offerings and transform technologies to serve this target. We started working with a consulting firm for calculating and reporting our carbon and water footprint. This will also help us to understand points to develop and transform the business.”