As a leading European manufacturer of technical textiles and geosynthetics, Thrace NG operates an integrated manufacturing facility encompassing weaving, nonwoven production, finishing, and packaging. With 119 looms in its weaving section and fabric rolls reaching up to 5.4 meters in width and 1.6 tons in weight, efficient in-plant material handling is essential to maintaining smooth production flows. However, conventional handling methods have created several operational challenges. The aging overhead crane system used for warp beam transportation requires manual coordination for lifting, positioning, and placement, increasing operational complexity and maintenance demands. Meanwhile, forklifts are used to transport fabric rolls from individual loom winders, creating additional traffic in workshop aisles and requiring operators to locate and maneuver around materials. Handling large, heavy rolls also increases the risk of damage to fabric edges and surfaces. In certain processes, the absence of dedicated handling equipment further increases reliance on manual labor and overhead lifting, creating bottlenecks in production logistics.

To address these challenges, Thrace NG required practical material handling solutions tailored to different stages of its integrated production processes. For warp beam handling, the company needed a ground-based transporter to replace its aging overhead crane system, simplify operations, and improve positioning convenience. For fabric roll handling, dedicated equipment was required to reduce manual intervention and improve transportation efficiency in previously unequipped processes. At the weaving stage, the scale of operations—with 119 loom winders generating fabric rolls for subsequent packaging—created a need for automated unloading and transportation to designated buffer racks. Beyond physical transportation, the AGV solution also needed to communicate with the customer's Manufacturing Execution System (MES) through an HTTP REST interface to receive tasks and coordinate material flows. These requirements called for a combination of specialized transport equipment and automated logistics solutions that could fit into existing production workflows.

SUNTECH was able to address Thrace NG's diverse material handling requirements through a portfolio of specialized equipment and automated logistics solutions. Building on the earlier cooperation with Thrace Polyfilms and the successful initial equipment procurement by Thrace NG in 2025, the partnership expanded in 2026 to include an ST-MBT-05 warp beam transporter, an ST-MBT-01II for fabric roll handling, and two ST-AGVs for automated fabric roll unloading and transportation. Rather than relying on a single type of equipment, Thrace NG could select solutions suited to distinct handling scenarios across its production processes. For the AGV project, SUNTECH also adopted a flexible implementation approach to accommodate the customer's production schedule. The project proceeded based on the current solution version while outstanding interface details involving automatic doors, rack light curtains, and MES integration were coordinated during production and commissioning. This approach helped the project move forward while allowing technical details to be addressed progressively. The expanding cooperation reflects SUNTECH's ability to provide application-specific material handling equipment and support the gradual advancement of automation within a complex technical textile manufacturing environment.