Turkish knit fabric leader Ekoten Tekstil has completed a definitive shift in its quality framework, transitioning from reactive manual checks to an AI-driven real-time prevention system. Following an expansive pilot, the İzmir-based manufacturer has integrated automated inspection across its high-capacity weft-knitting lines. The implementation addresses a critical industry pain point: defects often remain invisible until the resource-intensive dyeing stage. By utilizing CNN-based deep learning models with 95 per cent detection accuracy, Ekoten’s system now identifies irregularities - such as elastane lines, oil spots, and yarn inconsistencies - the moment they occur, automatically halting machines to prevent compounded fabric loss.
Operational gains and environmental ROI
Data from a year-long assessment in 2025 reveals, AI deployment prevented over 2,450 hours of defective production and avoided the creation of 32,100 kg of faulty fabric. Beyond material savings, the move optimized energy efficiency, saving approximately 289,000 kWh of electricity and reducing CO₂ emissions by over 71 tons. This technological leap has significantly increased throughput, with inspection speeds rising from a manual average of 15 m per minute to 50 m per minute. By minimizing re-dyeing and reprocessing, the system also directly conserves water - a vital metric for Ekoten’s CDP Climate Change 'A' rating.
Scaling circularity through digital traceability
The strategic value of Ekoten's AI adoption lies in its ‘Digital Roll Quality Reports’ and precise defect coordinate mapping. This level of granularity enables a ‘circular by design’ approach, where production data is integrated with machine settings to forecast maintenance needs. As Ekoten targets a 100 per cent traceability mandate for its global activewear and performance partners, the integration of AI-led inspection acts as a hedge against rising raw material costs. The industry now understands that optimizing production processes is the only way to achieve true sustainability, noted leadership, reinforcing Ekoten’s roadmap to remain a top-tier supplier in the competitive European and North American markets.
Ekoten Tekstil: A sustainable knit specialist
A subsidiary of Sun Tekstil, Ekoten Tekstil is a leading Turkish manufacturer of high-quality knitted fabrics for fashion, military, and sportswear. Operating a massive facility near İzmir with a daily capacity of 40 tonnes, it specializes in technical dyeing and digital printing. Ekoten plans to sustain its market leadership through continued $10 million+ investments in digitalization and green manufacturing.
