Oerlikon Barmag Engineering Solutions from one source.
Introduction
Overview
Projects
Contacts
Oerlikon Barmag – a brief history The history of Barmag began in 1922 in the form of Barmer Maschinenfabrik AG. Founded by Glanzstoff (Akzo in its current reincarnation), Barmag manufactured machines for producing viscose exclusively for its parent company’s production facilities. The industrial exploitation of polyamide as a raw material for the textile industry marked the beginning of Barmag’s development into a globally-active company. In the 1960s – with the emergence of polyester as a textile raw material – Barmag began to expand as a result of acquisitions and collaborations in the – at the time – most important markets, namely the USA, China and India. The advent of the new millennium was also a turning point for Barmag, as the company transformed itself from a mere machine maker into a solutions provider for the manmade fiber industry. The service range was expanded to comply with the growing demand of manmade fiber manufacturers for comprehensive engineering services and complete production infrastructures: Oerlikon Barmag Engineering (OBE) was born. This allowed Oerlikon Barmag to become a partner for turn-key project solutions – starting with the granulate, all the way through to the finished fabric.
The requirements with regard to the efficiency of manmade fiber production in conjunction with high expectations in terms of product quality are motivating ever more yarn manufacturers to focus on their own in-house production facilities for raw materials. Oerlikon Barmag picked up on these challenges and expanded its product portfolio in 2008 to include poly-condensation systems for manufacturing polyester. These systems are suitable for manufacturing fiber grade and bottle grade products. Through systematic adaptation to the market requirements, Oerlikon Barmag is now a long-term and reliable partner for its customers throughout the world.
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Introduction
Overview
Projects
Contacts
Oerlikon Barmag Engineering - Turnkey solutions for guaranteed endproducts Engineering is one of the three supporting columns of Oerlikon Textile‘s Total Solutions philosophy. In combination with cutting-edge technology and a comprehensive global service offering, engineering meets customer demand for an overall solution from a single source. The growing demand for engineering services – particularly from various newcomers to the fiber/filament manufacturing and processing sector – has resulted in the setting up of a Barmag-internal engineering division. Many years of experience in textile machine construction and the Oerlikon Textiles‘ strong global network form a solid basis and the perfect prerequisites for Oerlikon Barmag as a provider of entire process chains for manmade fibers. Many textile producers depend on the import of intermediate products such as granulate, partially oriented yarn (POY), fully oriented yarn (FDY) or texturized yarn (DTY) which means that they have little influence on delivery times or on yarn quality. Having your own polymerization, spinning/ draw-winding to the draw texturing equipment, however, opens up the
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opportunity to produce yarn independent of intermediate products deliveries and to determine and control the yarn resp. final product quality. Thus, it is possible to quickly and flexibly react to changes in the market. Harmonized chain of polymerization, spinning and texturing machines allow efficient production which results in an increase of added value for the customer and keeping the margin in house. Furthermore, Oerlikon Barmag will cater for a harmonization of all machines and lines in an optimal way and will provide the respective know-how. Today, the Oerlikon Barmag Engineering department possesses the process and engineering know-how to build: Turnkey delivery of: n Polycondensation plants for textile and bottle grade PET, n Extrusion spinning and direct spinning plants for commodity yarns, POY, FDY, HOY (for polymers such as PET, PA 6, PA 6.6, PP, PTT, PBT and PLA), n Technology for microfiber, n Technology for bi-component yarns, n Technology for spun dyed and modified yarn, n PET/PA6 extrusion spinning plants for industrial yarn like tire cord, etc., elastane plant, geotextiles, n Technology for draw texturized yarns (DTY).
Introduction
Overview
Projects
Contacts
Oerlikon Barmag Engineering Starting from the feasibility study to the implementation of projects, our customer will receive all services from a single source. Oerlikon Barmag Engineering delivers the following services: n feasibility study, n consulting services, n engineering services, n plant layout, n basic and detail engineering, n procurement, expediting and inspection, n process know-how and technology, n guarantees for product and production, n supervision of erection and start-up, n operators‘ training, n site management.
Examples for engineering services are: n project management, n plant layout and process engineering, n mechanical engineering, n DCS, electrical and instrumentation engineering, n PCS engineering, n piping engineering, n energies and utilities engineering, n data and technical documentation, n operation instructions.
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Introduction
Overview
Projects
Contacts
Barmag‘s engineering projects are in operation all over the world
1. India, 2. India,
PET POY direct spinning PET Polycondensation plant POY/FDY direct spinning 3. India, PET/POY direct spinning PA6 Industrial yarn PET CP textile grade 4. Indonesia, PA6 Industrial yarn 5. Vietnam, PET POY 6. PR China, PET HT/HMLS Industrial yarn 7. PR China, PET POY/FDY 8. PR China, PET HMLS Industrial yarn 9. Belarus, PET POY + DTY PA6 Industrial yarn PET Industrial yarn PET HMLS Industrial yarn 10. Iran, PET POY 11. Turkey, POY direct spinning Turkey, PET/PA 6.6 Industrial yarn 12. Saudi Arabia PET Industrial yarn 13. Egypt, PET POY + DTY PET FDY 14. Germany, Acrilic staple fiber 15. Brazil, PET HT/LS/SLS/HMLS Industrial yarn 16. Morocco PET FDY 17. Syria PA POY + DTY PET POY + DTY/FDY 18. Spain PET Industrial yarn PA6/PA6.6 POY/FDY
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Introduction
Overview
Projects
Contacts
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Introduction Engineering - Solutions Provider
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Overview
Projects
Contacts
Introduction
Overview
Projects
Contacts
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Introduction Spinning projects
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Overview
Projects
Contacts
Introduction
Overview
Projects
Contacts
Solution for dyed PET textile yarn with guarantees Location: Egypt Plant type: 12 Positions, 96-end PET FDY extrusion spinning plant, with yarn process guarantee
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Start up: June 2003 n
Scope of supply: n Chips conveying, storage n Chips crystallization, drying n MB chips drying, metering
Extruder, spinning, take up and accessories such as filter cleaning, godet exhaust system, laboratory, etc. Quench and take up air conditioning units Utility generation units like power generators, chillers, demineralised water and compressed air units Chemical and textile laboratories
Engineering & Construction: n Basic engineering n Detail engineering n Supervision of erection & start up
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Introduction
Overview
Projects
Contacts
Solution for PET direct spinning textile yarn with guarantees Location: PR China Plant type: 576 Positions, 4,320-end PET POY and 1,728-end PET FDY direct spinning plant, with yarn process guarantee Start up: April 2004
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Scope of supply: Polymer manifolds n Spinning and take up, incl. dowtherm boilers n
Engineering & Construction: n Basic engineering for manifolds, spinning, dowtherm and liquid HTM system n Detail engineering for manifolds, spinning, dowtherm and liquid HTM system n Supervision of erection & start up
Introduction
Overview
Projects
Contacts
Solution for PA6 fishing net yarn with guarantees Location: Indonesia Plant type: 12 Positions, 72-end PA6 industrial yarn extrusion spinning plant, with yarn process guarantee
Scope of supply: Extruder, spinning, take up and accessories such as spinneret cleaning system, laboratory,etc. n Quench and take up air conditioning units n
Start up: April 2004 Engineering & Construction: n Basic engineering n Detail engineering n Supervision of erection & start up
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Introduction
Overview
Projects
Contacts
Solution for dyed PET textile yarn with guarantees Location: Belarus Plant type: 72 Positions, 288-end PET POY extrusion spinning plant, with yarn process guarantee
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Start up: September 2004 Scope of supply: n Chips conveying, storage n Chips crystallization, drying n MB chips drying, metering n Extruder, spinning, take up and accessories such as filter & spinneret cleaning, laboratory, etc.
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DTY machines Automation system Quench air conditioning units Utility generation units like chillers, demineralised water and compressed air units
Engineering & Construction: n Basic engineering n Detail engineering n Supervision of erection & start up
Introduction
Overview
Projects
Contacts
Solution for PET direct spinning textile yarn with guarantees Location: Turkey Plant type: 24 Positions, 192-end PET POY Direct spinning plant, with yarn process guarantee
Scope of supply: Polymer transfer line, including polymer piping, Booster pump, polymer cooler, polymer valves, HTM cooler n Spinning and take up n
Start up: March 2004 Engineering & Construction: n Basic engineering for polymer line, spinning, dowtherm and liquid HTM system n Detail engineering for polymer line, spinning, dowtherm and liquid HTM system n Supervision of erection & start up
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Introduction
Overview
Projects
Contacts
Solution for PET tyre cord with guarantees Location: PR China Plant type: 6 Positions, 18-end PET industrial yarn extrusion spinning plant, with yarn process guarantee
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Extruder, spinning, take up and accessories such as spinneret cleaning system Laboratory Quench and take up air conditioning units Utility generation units like compressed air
Start up: January 2005
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Scope of supply: n Chips conveying & storage n Continuous solid state polycondensation unit n Plant Operation Center
Engineering & Construction: n Basic engineering n Detail engineering n Supervision of erection & start up
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Introduction
Overview
Projects
Contacts
Solution for PET direct spinning textile yarn with guarantees Location: India Plant type: 108 Positions, 1,080-end PET POY direct spinning plant, with yarn process guarantee
Scope of supply: Polymer transfer line, including polymer piping, Booster pump, polymer cooler, polymer valves, HTM cooler n Spinning and take up n
Start up: May 2005 Engineering & Construction: n Basic engineering for polymerline, spinning, dowtherm and liquid HTM system n Detail engineering for polymer line, spinning, dowtherm and liquid HTM system n Supervision of erection & start up
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Introduction
Overview
Projects
Contacts
Solution for coloured PET textile yarn with guarantees Location: Egypt Plant type: 12 Positions, 96-end PET FDY extrusion spinning plant, with yarn process guarantee
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Quench and take up air conditioning units Utility generation units like power generators, chillers, determineralised water and compressed air units, Chemical and Textile laboratories Demineralised water and compressed air units
Start up: November 2005
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Scope of supply: n Chips conveying, storage n Chips crystallization, drying n MB chips drying, metering n Extruder, spinning, take up and accessories such as filter cleaning, godet exhaust system, laboratory,etc.
Engineering & Construction: n Basic engineering n Detail engineering n Supervision of erection & start up
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Introduction
Overview
Projects
Contacts
Solution for PET direct spinning textile yarn with guarantees Location: India Plant type: 1,200 Positions, PET POY / FDY direct spinning plant, with yarn process guarantee Start up: December 2005
Scope of supply: Spinning manifolds n Spinning and take up n
Engineering & Construction: n Basic engineering for manifolds, spinning, dowtherm system n Detail engineering for manifolds & spinning n Supervision of erection & start up
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Introduction
Overview
Projects
Solution for PET tyre cord and HT yarn with guarantees Location: Belarus Plant type: PET industrial yarn extrusion spinning plant, with yarn process guarantee
Scope of supply: Chips conveying & storage n Chips drying unit n Extruder, spinning, take up and accessories n
Start up: March 2006 Engineering & Construction: n Basic engineering n Detail engineering n Supervision of erection & start up
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Contacts
Introduction
Overview
Projects
Contacts
Solution for PET direct spinning textile yarn with guarantees Location: India
Scope of supply: Polymer transfer line, including polymer piping, Booster pump, polymer cooler, polymer valves, HTM cooler n Spinning and take up n
Plant type: 384 Positions, 3,840-end PET POY direct spinning plant, with yarn process guarantee Start up: July 2006
Engineering & Construction: n Basic engineering for polymer line, spinning, dowtherm and liquid HTM system n Detail engineering for polymer line & spinning n Supervision of erection & start up
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Introduction
Overview
Projects
Contacts
Solution for PET textile yarn with guarantees Location: Vietnam Plant type: 24 Positions, 240-end PET POY extrusion spinning plant, with yarn process guarantee Start up: October 2006
Scope of supply: Chips conveying & storage, chips crystallization & drying n Extruder, spinning, take up and accessories such as spin finish mixing system, spin pack preheating, spinneret cleaning system, laboratory, etc. n Quench and take up air conditioning units n Utility generation units like chillers, demineralised water and compressed air units n
Engineering & Construction: n Basic engineering n Detail engineering n Supervision of erection & start up
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Introduction
Overview
Projects
Contacts
Total Solution for PET technical yarn Location: Brazil Plant type: 4x4 Positions, 96-end PET technical yarn extrusion spinning plant, with yarn process guarantees Start up: December 2008
Scope of delivery: Chips conveying, storage n Extruder, spinning and take up n Quench air and take up air conditioning units n Utility generation such as demineralized water and compressed air n Accessories such as spinneret cleaning system, chemical and textile laboratory n
Engineering and Construction: n Project Management n Basic Engineering n Detail Engineering n Supervision of erection and start up
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Introduction
Overview
Projects
Contacts
Solution for PA6 spinning textile yarn with guarantees Location: Syria Plant type: 8 Positions, 80-end PA6 POY / HOY spinning plant, with yarn process guarantee
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Start up: March 2009 Scope of delivery: n Chips conveying, storage n MB chips drying and metering n Extruder, spinning and take up
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Quench air and take up air conditioning system Utility generation such as chiller, demineralized water and compressed air Chemical and Textile laboratory
Engineering and Construction: n Project Management n Basic Engineering n Detail Engineering n Supervision of erection and start up
Introduction
Overview
Projects
Contacts
Total Solution for dyed PET textile yarn with guarantees Location: Belarus Plant type: 24 Positions, 80-end PET-POY and 160-end PET-FDY extrusion spinning plant, with yarn process guarantee
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Start up: July 2009 Scope of delivery: n Chips conveying, storage n Chips crystallization, drying n MB chips drying, metering
Extruder, spinning and take up Automation system Quench air conditioning units Utility generation units such as chillers and compressed air
Engineering and Construction: n Project Management n Basic Engineering n Detail Engineering n Supervision of erection and start up
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Introduction
Overview
Projects
Contacts
Solution for PET spinning industrial yarn with guarantees Location: Saudi Arabia Plant type: 8 Positions, 32-end PET IDY-SLS spinning plant, with yarn process guarantee
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Start up: December 2009
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Extension: scheduled for July 2013 Scope of delivery: n SSPC n Chips conveying, storage n Chips crystallization and drying
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Extruder, spinning and take up Quench air and take up air conditioning system Utility generation such as chiller, demineralized water and compressed air Accessories such as mechanical workshop Chemical and textile laboratory
Engineering and Construction: n Project Management n Basic Engineering n Detail Engineering n Supervision of erection and start up
Introduction
Overview
Projects
Contacts
Total Solution for PET industrial yarn with guarantees Location: Spain Plant type: 2 Positions, 6-end PET industrial yarn extrusion spinning plant, with yarn process guarantee Start up: April 2010 Extension: Start-up July 2011
Scope of delivery: Chips conveying, storage n Extruder, spinning and take up n Quench air and take up air conditioning units n Accessories n
Engineering and Construction: n Project Management n Basic Engineering n Detail Engineering n Supervision of erection and start up
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Introduction
Overview
Projects
Contacts
Solution for PET textile yarn with guarantees Location: Iran Plant type: 48 Positions, 480-end PET POY extrusion spinning plant, with yarn process guarantee
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Start up: December 2010 Scope of supply: Plant operation centre, n Chips conveying, storage, crystallization, drying, spinning, take up and accessories n
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Quench air and take up air conditioning Chemical and Textile laboratories Spinfinish mixing and handling Utility generation such as chiller, demineralised water and compressed air
Engineering & Construction: n Basic engineering n Detail engineering n Supervision of erection & start up
Introduction
Overview
Projects
Contacts
Solution for PET industrial yarn spinning with guarantees Location: PR China Plant type: 48 Positions, 384-end PET industrial yarn spinning plant, with yarn process guarantee
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Start up: March 2010 Scope of delivery: n Chips conveying, storage n MB chips drying and metering n Extruder, spinning and take up
Quench air and take up air conditioning system Utility generation such as chiller, demineralized water and compressed air Chemical and textile laboratory
Engineering and Construction: n Project Management n Basic Engineering n Detail Engineering n Supervision of erection and start up
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Introduction
Overview
Projects
Solution for dyed PET textile yarn
Location: Turkey Plant type: Conversion of 32 positions, 192-end PET-FDY from direct into extruder spinning Start up: March 2011
Scope of delivery: Chips crystallization, drying n MB chips drying, metering n Extruder, polymer filter n Plant Operation Center n
Engineering and Construction: n Project Management n Basic Engineering n Detail Engineering n Supervision of erection and start up
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Contacts
Introduction
Overview
Projects
Contacts
Polycondensation projects
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Introduction
Overview
Projects
Contacts
PET polycondensation From monomer to finished product The quality of raw materials is a decisive factor for the quality of the final product. Only vertically-integrated companies control all levels of the value-added chain - all others are reliant on their suppliers. With Oerlikon Barmag polycondensation, customers will reduce their dependencies and will be able to determine the characteristics of the raw material. With more than 80 years of experience, Oerlikon Barmag knows the requirements of filament spinners and converts them into processoptimized systems concepts. For the value-added chain - from the polycondensation, spinning through to the texturing - there is now one single contact partner - Oerlikon Barmag Engineering. This is the sole source for the customer - with just one contact partner both during the whole project and later within the working plant. Using the knowledge of producing fiber grade resin, it is just a step ahead to provide the knowledge and equipment for the production of bottle grade resin.
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Customers will draw on proven technology and top-quality, internally-developed products. All components have been long-term tested and guarantee high system availability. Oerlikon Barmag´s innovative system design, lower energy and utility consumption - as well as fewer emissions and less waste water - considerably increase the system‘s efficiency. An experienced and dedicated engineering team will accompany the customer throughout all project phases - from planning all the way through to market success. n Feasibility study and consulting services n Engineering services n Basic and detail engineering n Commissioning and start up n Project management n Guarantees for product quality and capacity
Introduction
Overview
Projects
Contacts
Solution for continuous polycondensation for filament yarn Location: India Plant type: 400 tpd CP PET fiber grade, with process guarantee
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Start up: August 2009 Scope of delivery: n PTA conveying n Raw material preparation n Inline EG recovery n Esterification and polycondensation
Granulation Chips storage and bagging Utility generation such as HTM, refrigeration, demineralized water, nitrogen supply and compressed air
Engineering and Construction: n Project Management n Basic Engineering n Detail Engineering n Supervision of erection and start up
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Introduction
Overview
Projects
Contacts
Solution for PET chips production with guarantees Location: India Plant type: 600 tpd CP bottle grade, with process guarantees
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Start up: scheduled for February 2012 Scope of delivery: n PTA conveying n Raw material preparation n Inline EG recovery n Esterification and polycondensation n Granulation
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SSPC Chips storage and bagging Utility generation such as HTM, refrigeration, demineralized water, nitrogen supply and compressed air
Engineering and Construction: n Project Management n Basic Engineering n Detail Engineering n Supervision of erection and start up
Introduction
Overview
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Contacts
Solution for PET chips production with guarantees Location: Egypt
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Plant type: 2 x 600 tpd CP bottle grade, with process guarantee Start up: scheduled for June 2012 Scope of delivery: n PTA conveying n Raw material preparation n Inline EG recovery n Esterification and polycondensation
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Granulation SSPC Chips storage and bagging Utility generation such as HTM, refrigeration, demineralized water, nitrogen supply and compressed air
Engineering and Construction: n Project Management n Basic Engineering n Detail Engineering n Supervision of erection and start up
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Introduction
Oerlikon Barmag Zweigniederlassung der Oerlikon GmbH & Co. KG P.O. Box 11 02 40 42862 Remscheid GERMANY Phone +49 21 91 67-0 Fax +49 21 91 67-12 04 www.oerlikontextile.com info.barmag@oerlikon.com Oerlikon Textile Inc. 8801 South Boulevard P.O. Box 70 46 Charlotte N.C. 28241 U.S.A. Phone +1 704 916 42 68 Fax +1 704 916 42 09 info.charlotte@oerlikon.com
Overview
Projects
Contacts
Oerlikon Textile Far East Ltd. Room 2806 China Resources Building 26 Harbour Road Wanchai, HONG KONG P.R.CHINA Phone +852 28 27 43 14 Fax +852 28 27 52 50 info.hk@oerlikon.com Oerlikon Textile India Pvt. Ltd. Empire Industries Complex 414, Senapati Bapat Marg Lower Parel (West) Mumbay 400 013 INDIA Phone +91 22 6652 7900 Fax +91 22 6652 7901 management.bom@oerlikon.com
The information supplied in this brochure is for guidance only. We reserve the right to modify it at any time. April 2011 Edition 3 36