Sytec One: new BCF machine Stefan Kalies, Martin Rademacher, Oerlikon Neumag, Neumünster/Germany The new developed BCF machine Sytec One by Oerlikon Neumag is a plant with only 1 yarn end per position. With this new BCF technology, each yarn has its own spinning pump, one spinning duct, own godets, one texturing unit, one cooling drum and its own single end winder. It is a re-invention of the BCF technology for an increase in throughput, for improvement of yarn quality and a reduction of investment. During the last decades, new developments in BCF technology mainly focused on 3 targets: • increase of throughput per yarn end • improvement of yarn quality • reduction of investment costs (per ton of produced yarn). With the development of the new generation of BCF plants, Oerlikon Neumag, Neumünster/Germany, concentrated on these targets but left the traditional paths of development which would mean increasing the number of yarn ends per position. After 1, 2, 3, 4 and for special processes even 6 yarn ends per position, 8 would be the logical consequence of the development work. However, a constantly increasing number of yarns per position also results in many disadvantages for the yarn producer. For example, the plant ef-
ficiency decreases with the increasing number of yarns. If, for example, today one yarn breaks on a 4-end plant, all 4 yarns break, even though 3 of them are okay. Therefore a 4-end machine not only produces double the waste of a 2-end machine, but also reduces the plant availability. Furthermore, the installed components become larger, more complicated and more demanding if they are simultaneously used by more and more yarns. Each additional end per position inevitably makes the machine and its operation more complicated.
- Perfect yarn path Sytec One has a real and perfect symmetrical yarn path. The yarn path is absolutely straight from the spinning system up to the texturing unit and needs only few yarn guides and no reversing angles in pro-
cess-critical positions, such as the inlet area.
- Higher efficiency The efficiency significantly increases. Only the yarn which has the problem breaks. All other yarns are not affected and keep on running. Therefore a waste rate of less than 1% with an absolutely higher production capacity (see below) can be guaranteed.
- Higher plant availability Only one and not several yarn ends has to be switched off during maintenance works or when changing the spinnerets. This significantly increases the plant availability (production capacity) of the machine.
- Higher production capacity Based on the very good yarn path and new developments, the process speeds are about 10-40% higher (depending on the product). At the same time, better yarn qualities and a higher machine efficiency can be attained.
- More constant retention time of the polymer If, with traditional technology (i.e. 2 positions with 3 yarn ends each), 1 position is switched off for changing the spinneret, the retention time of the polymer in the extrusion doubles which, under certain
Fig. 1 Sytec One draw texturing section - operating level (Oerlikon Neumag)
Man-Made Fiber Year Book 2007
Fig. 2 Sytec One texturing unit with multi wrap cooling drum
Fig. 3 Sytec One inlet section with Temco PremiJet
conditions, may lead to a stripe formation in the carpet. With the 1-end technology the retention time remains more or less constant.
- Simplified operation Even the operability of the plant can be considerably facilitated due to the single yarn process. The threading time has been reduced by 70%. The assembly and disassembly of the texturing nozzles and lamella chambers, as well as the handling of the components during maintenance works have also been optimized.
- Preventing operating faults A frequent occurrence with multi-yarn end processes is stripes in the carpet due to the different total titer of the carpet yarn (different numbers of filaments). These are caused by the fact that the bundle of single filaments coming out of the spinning system is not correctly separated and then combined to a complete yarn end. The separation of the single filaments is logically not necessary with a single end plant so that this frequently occurring fault is thus completely prevented.
- Facilitated process trouble shooting With several yarn ends per position, it is difficult to determine which yarn broke first and what was the reason for a fault. With the single end concept, the fault analysis is much easier because it is ab-
solutely clear which yarn broke. Therefore subsequent breaks can be avoided which again increases efficiency.
- Fully automatable Sytec One can be completely automated from automatic unpacking of the tubes via tube transport to the winders, bobbin removal, down to knotting, labeling and packing. An operator is only required for threading and can easily operate up to 54 positions. This is enabled by the strict separation of the operating and automating section of the plant. Nevertheless, the plant can also be operated just manually. There are many more advantages considering the potential of a single end plant. Carpet yarns were produced during test runs which have, up to now, not been produced with multi-end technologies. The yarn producer therefore not only has a larger flexibility during yarn production, but also a much higher innovation potential with regard to new designs and qualities. In the past, much has been discussed about the feasibility and economy of single end concepts. However through the application of new technologies, the presumable disadvantages of single end machines, such as for example the high manufacturing costs, do nowadays not apply any more. Therefore, in comparison with the presently leading machine technologies on the market, this new
plant is not only completely competitive with regard to the investment costs but also regarding the energy consumptions. The development of this new BCF generation not only necessitated a simple reduction of the number of ends per position. In order to exploit the full potential, nearly all components have been adapted or newly developed in respect of the specific demands of the single end process. For example, a unique, integrated spin finish and pre-tangling nozzle has been developed with Oerlikon Heberlein Temco which will also be introduced at the ITMA 2007 in Munich/Germany. The spin finish application is much more uniform and in comparison to traditional technologies, much higher. Due to a closed construction, there are no more spin finish splashes which contaminate the machine or which could cause accidents (by slipping). The spin finish remains on the yarn and does not land anywhere on the machine. Moreover, the texturing system has been consequently further developed and the performance and operation improved. Ceramic texturing nozzles and ceramic lamellae belong to the standard equipment of this new generation of texturing systems and guarantee absolutely no wear under production conditions. The cooling of the textured yarn has also been completely renewed and is now effected by a multiwrap cooling drum with which a much higher retention time of the carpet yarn and therefore a practically perfect crimp structure can be attained. Definite quality improvements have been realized in particular for high-grade velour qualities such as for the automotive industry. The new single end winder is furthermore based on the proven wing traversing system and is laid out for production speeds up to 4,000 m/min. The winder is also equipped with an automatic tube feeding system. The Dutch company Select Yarns, a member of the Betap Group, is the first carpet producer to have chosen the new BCF technology. Sytec One will complement the previous BCF machine program of Oerlikon Neumag which presently consists of the S5 which has been on the market since 2001, and the S3, which is particularly laid out for smaller production capacities. The machine will be presented at the Oerlikon Textile stand during the ITMA.
Reprint from Man-Made Fiber Year Book 2007, 65-66 Deutscher Fachverlag GmbH, 60326 Frankfurt am Main/Germany Man-Made Fiber Year Book 2007
"PremiJET" â€“ Preparation and migration in the BCF spinning process in one device Oerlikon Heberlein Temco, Hammelburg, Germany Oerlikon Neumag, NeumĂźnster, Germany ITV, Institute of Textile Technology and Process Engineering Denkendorf, Germany PremiJET is a preparation and migration device in a closed system (patent pending). This cooperation project has been developed, tested and realized by three competent and mutually complementing cooperation partners. The project is supported and funded by Germany's Federal Ministry of Education and Research. The PremiJET device allows a highly efficient, environment-friendly and economic application with uniform dispersion of the procedural indispensable spin finish even at high yarn speeds (up to 6000 m/min winding speed). In contrast to the currently used standard open application methods the PremiJET applies the spin finish in a closed device.
The subsequent migration process, that distributes the spin finish still better on the filaments and blows off excess spin finish from the yarn has been integrated into the closed device. The excess spin finish is absorbed by the PremiJET device and can be recirculated. Thus the spin finish consumption is reduced without compromising spin finish application,
costs are saved. The air interlacing is necessary for the migration of the filaments, which get thereby an inter-filament-cohesion. In addition, a better and more even migration of the spin finish over the filament surface is achieved. Because of the encapsulation the contamination of the spinning machine and of the room with spin finish as well as the contamination of the air with oil aerosol is effectively avoided and the reclamation and reuse of the blown off spin finish shall be ensured. The PremiJET device causes a better migration of the spin finish and the consumption of the spin finish can be highly reduced.
After closing the device no spin finish will discharge
For easy threading the PremiJET device can be opened
Loss of oil in %
Man-Made Fiber Year Book 2007