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Solutions for POY manufacturing


As creative as the market Oerlikon Barmag, a division of Oerlikon Textile GmbH & Co. KG with sites in Remscheid, Chemnitz, Wuxi and Suzhou (both People’s Republic of China), was founded as Barmag AG in 1922. The company is the world market leader for spinning systems and equipment for manmade fibers, such as polyester, nylon and polypropylene, and texturing machines and – as a service provider – offers engineering solutions for the entire textile value added chain. High-tech from the market leader Its core competencies also include the production of the associated components for manufacturing manmade fibers, such as extruders, winders, pumps and godets. As a future oriented company Oerlikon Barmag’s research

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POY solutions – Oerlikon Barmag

and development is driven by the idea of energy-efficiency and sustainable technologies. With the expansion of the product range to include poly-condensation systems and their key components, the company now caters to the entire process – from the monomer all the way through to the textured yarn. At your service The primary Oerlikon Barmag markets are Asia, and China and India in particular, as well as the Middle East and Europe. Correspondingly, the company – with its approximately 1,600 employees – has a worldwide presence in 120 countries as part of the Oerlikon Textile network of production, sales and distribution and service organizations. At the Oerlikon Barmag R&D Center – the largest of its kind in the world – within the company’s head-

quarters in Remscheid, highly-qualified engineers and technicians develop innovative and technologically-leading products for tomorrow’s world. Oerlikon Barmag machines and components rely on a large number of registered trademarks and international patents.


Table of contents Plant engineering

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POY spinning solutions

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e-save – Energy saving and more

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Process solutions

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Key components Extrusion equipment Pumps Mixing and metering in polymer processing Spinning head series Spin packs Quenching systems WINGS

16 18 19 20 22 23 24 26

Plant Operation Center (POC)

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Downstream process

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SUN – Service Unlimited

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POY solutions – Oerlikon Barmag

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Plant engineering Consulting, engineering, plant construction and high-tech machinery – the whole package from a single source. Many years of experience in textile machine construction and Oerlikon Textile’s strong global network form a solid basis and the perfect prerequisites for Oerlikon Barmag as a solutions provider. Many texturizers depend on the import of POY which means that they have little influence on delivery times or on yarn quality. Having your own spinning equipment, however, opens up the opportunity to produce yarn independent of POY deliveries and to determine and control the yarn quality. Thus, it is possible to quickly and flexibly react to changes in the market.

Oerlikon Barmag plant engineering delivers the following services: - feasibility study - consulting services - engineering services - basic and detailed engineering - guarantees for product and production

A harmonized chain of polycondensation, spinning and texturing machines allows efficient production which results in an increase of added value for the customer. Furthermore, Oerlikon Barmag will cater for a harmonization of all machines and lines in an optimal way and will provide the respective know-how.

Examples for engineering services are: - project management - plant layout and process engineering - machinery engineering - electrical and instrumentation engineering - piping engineering - polycondensation

In plant engineering and construction, the term plant design means turnkey construction. This means that starting from the feasibility study through to the implementation of projects, the customer will receive all services from a single source.

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POY solutions – Oerlikon Barmag

Oerlikon Barmag plant engineering looks after the complete processes, from the CP to the DTY machine, and includes chip handling, auxiliary plants, utility plants, general electrics as well as the respective documentation.


A selection of reference projects

Engineering is one of the three supporting columns of Oerlikon Barmag’s 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. A choice of projects demonstrates Oerlikon Barmag‘s expertise in the challenging field of plant engineering

Project: The project covers a Polyester POY direct spinning system from polycondensation to winding. The polycondensation has a capacity of 100,000 tons per year. The spinning section consists of 6 lines with 24 positions at 10-end/ 20-end. For winding, the yarn producer relied on WINGS, the new Oerlikon Barmag winder with the drawing zone included. Location: India Start up: Mai 2009 Scope of supply: - Polycondensation - Transfer line from Polycondensation to spinning - spinning, take-up Engineering & Construction: - Basic engineering - Detail engineering - Supervision of erection & start-up

Project: The project covers a Polyester POY spinning system from chips drying system to winding. The spinning section consists of 2 lines with 8 positions at 10-end. Location: Belarus Start up: 2009 Scope of supply: - Air conditioning system - Chips drying and chips conveying system - Chips / masterbatch dosing system - 2 x 4 position PET POY spinning lines, take-up - Accessories & utilities Engineering & construction: - Basic engineering - Detail engineering - Supervision of erection & start-up

Project: Dyed PET textile yarn with guarantees Location: Vietnam Plant type: 24 positions, 10-end PET POY extrusion spinning plant, with yarn guarantee Start up: October 2006 Scope of supply: - Chips conveying & storage, chips crystallisation & drying - Extruder, spinning, take-up and accessories - Air conditioning system - Accessories & utilities Engineering & construction: - Basic engineering - Detailed engineering - Supervision of erection & start-up

POY solutions – Oerlikon Barmag

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POY spinning solutions For more than 50 years now, POY yarns made from polyester and polyamides have formed the majority of textile filaments and hence also the most important sector for all textile yarn manufacturers across the globe. In this period, a continual increase in systems productivity has been noticeable with rises in the number of yarn ends, from originally 2 ends to currently up to 20 ends per position.

Yarn manufacturers – whether providers of standard qualities or niche products – are faced with increasing pressure on efficiency. In demand are methods and means that increase the performance and quality of the production process. This is the starting point for WINGS. The WINGS concept Developed with the objective of increasing the productivity and efficiency of POY systems, the revolutionary concept bears the solution in its very name: Winding INtegrated Godet Solution – in short WINGS. The winder as a complete take-up machine removes the spatial separation of godets and winders common today. Faster In conventional spinning systems, the drawing unit and the take-up unit form two levels beneath the spinning unit, so that the yarn string-up needs to be carried out by two operators. In contrast, WINGS can be completely operated from floor-level and all elements are laid out at eye level. Consequently, this significantly reduces the time required for yarn string-up by more than 50%; time in which top-quality POY yarn – and not waste – can be produced. Furthermore, this simplification of the string-up process considerably reduces the risk of operator errors. WINGS simplifies and shortens the installation of the system. The entire WINGS take-up concept is delivered from Germany as a completely pre6

POY solutions – Oerlikon Barmag

installed and tested unit. All that is required onsite is the connection of the power and compressed air supplies. This concept allows a significantly earlier production start compared to a conventional POY line. Furthermore, there are considerably fewer requirements for the building in the case of the WINGS concept. Conventional layouts require the elaborate installation of floor tracks and the almost millimeter-accurate alignment of the drawing unit and winder. As a result of the new 3-point-concept, spinning positions equipped with WINGS make no special demands on the evenness of the floor and hence provide optimal process and, hence, product quality even in the case of slight floor unevenness, therefore entirely dispensing with costs for accurate alignment. Better The new WINGS concept has been systematically geared towards reducing the cord angle within the drawing unit. Insofar as is prudent, points with a high wrapping angle have been equipped with rotating and hence friction-free yarn guides. The sum of all deflection angles in the drawing unit is now approx. 7°.This is an absolute reduction of 21° compared to conventional POY drawing units. Therefore, yarn manufacturers are able to spin considerably more even yarns with WINGS. For example, the CV% values for tenacity and elongation can be reduced by up to 40% in com-

parison to conventional POY drawing units. More energy conscious Due to its highly efficient intermingling concept, the new WINGS tangle jet enables further savings in comparison with other POY winding systems. In addition to the waste incurred for normal string-up processes, the reduced string-up times for WINGS also require less compressed air. This results in energy savings of 25-45 %. More frugal WINGS is an autonomous unit with an integrated control cabinet. Removing the drawing unit offers greater freedom in the positioning of the machines. Here, manufacturers can plan conventional layouts so as to create more space for air-conditioning channels, for example. However, WINGS also permits a considerably tighter layout of the spinning unit. The space requirement is reduced by at least 25% compared to conventional systems. A new spinning unit building for a given production capacity can hence be much more compact, allowing companies to reduce the costs. And integrating WINGS into an existing spinning plant building offers benefits in terms of the reduced height of the components.


POY solutions – Oerlikon Barmag

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e-save – energy saving and more Think e-save and reduce your production costs! Under this motto Oerlikon Barmag started promoting energy-conscious machines and components in 2005. The combination of high-performance machines and systems, high flexibility and low conversion costs is enabling manufacturers to be successful market players. The focus of e-save is on the reduction of the conversion costs. In 2005, Oerlikon Barmag developed and launched the e-save label, which is awarded to those components whose energy consumption has been significantly reduced compared to standard components available on the market. Demands and inquiries from our customers have encouraged us to systematically further research and develop the approaches we have already taken. Like a stone thrown into a lake, e-save is creating ever more positive repercussions. In addition to energy-efficient components, Oerlikon Barmag offers resource-minimizing solutions in many areas. Energy and environmental costs are also a not inconsiderable factor in POY production systems. Today, they already cause up to a third of the conversion costs of a spinning plant. All savings in this area benefit the local environment, while energy and resource efficiency are becoming ever more important locational factors on a global level.

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POY solutions – Oerlikon Barmag


There are numerous possibilities for sustainably lowering the consumption of valuable resources. Firstly, there are energyoptimized components, for example Oerlikon Barmag’s SP8x spinning beam, which consumes more than 40% less energy than other more common designs. In a POY spinning system with 144 positions, this generated an annual saving of approx. U$ 90,000. Reducing the consumption of controlled-processed air is an important objective of the EvoQuench. Radial quenching consumes 60-80% less air than cross-flow quenching – and can be used for manufacturing microfilaments and commodity yarns of up to 3 dpf. Multi-filament spinning saves energy However, the utilization of efficient components is only one step on the path to creating smart production processes. Restricting the examination to the spinning system alone does not take important factors into account. Within this context, the multi-filament capability should definitely be considered an energy-saving factor. Spinning 20-end POY using a spinning beam with DIO spinnerets and a quenching unit on 2 take-up positions is therefore considerably more efficient than two 10-end spinning positions. A decisive associated factor that influences the overall energy consumption is the air-conditioning system. Drives, heating systems, components that come into contact with the melt as well as the filaments radiate heat. If this heat radiation is reduced by means of excellent insulation, the air-conditioning system can be small, hence itself using less energy. Oerlikon Barmag – with its focus on innovation and technological leadership – provides a variety of machines, components and solutions that stand out through their excellent resource efficiency and thus easily fulfill the requirements defined by the e-save label.

POY solutions – Oerlikon Barmag

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Process solutions

Our customers can benefit from the comprehensive optimization of single processes along the textile value chain. Our big advantage is the fact that Oerlikon Textile serves the world’s largest spread of applications in the textile machinery industry. Oerlikon Barmag offers complete production lines from a single source – to offer the best possible solution – and we also work together with partners if special external expertise is necessary. Technology and support going hand in hand Innovative machines and systems are just part of the story. Oerlikon Barmag’s process solutions turn machines into teams. They integrate production processes and match every item of equipment perfectly to the next. Customers profit from Oerlikon Barmag’s comprehensive process know-how along the polycondensation, spinning and texturing steps in the textile value chain. Oerlikon Barmag’s solutions take a big weight off customers’ minds. Oerlikon Barmag’s one-stop shop covers everything from finance through to turnkey plants. Top machinery, comprehensive process skills, professional advice and service are all in the package.

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POY solutions – Oerlikon Barmag


POY solutions – Oerlikon Barmag

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Polyester POY

The optimized processes for manufacturing polyester POY on Oerlikon Barmag systems guarantee the best possible combination of number of ends and package weight. DTY and other downstream processes can be run at extremely high take-up speeds as a result of the excellent yarn evenness achieved. The best CV% values as well as AA-quality yarns are standard. The production process with 20 ends can be carried out using the hydraulic-split procedure. However, the requirements of a high yarn-to-yarn titer evenness require the double-in-one (DIO) technology. With this technology, two separate polymer melt flows are led through a package completely separately using their own spinning pump. This enables titer evenness identical to single packages while requiring 30% less space.

Microfibers There are different processes available for manufacturing polyester microfibers: cross-flow half-pipe quenching permits titers of between 75 and 150 den, whereby the titer of the individual filament lies between 0.5 and 1.5 dpf. Alternatively, the process using EvoQuench quenching allows for finer titers of between 30 and 400 den. This process enables titers for the individual filament to be between 0.34 and 3 dpf. Up to 288 ends can be manufactured using this technology. EvoQuench quenching reduces the quench air consumption by around 60% compared to cross-flow quenching, hence achieving considerable savings in the conversion costs.

The optimized production process is designed for low conversion costs as a result of low investment costs and – in comparison to standard spinning systems – low space requirements within the spinning unit. The yarn is wound onto individual WINGS machines, hence allowing the system to produce a high number of ends at high speed, while still permitting a package volume of 16.8 dm³. This also ensures full bobbin rates as the yarn path to each winder is completely separated. The process was optimized to the lowest angle of deflection, which enables low POY CV% values. For this reason, the material can handle the highest speeds in texturing and in further downstream processes.

Process Titer final Single filament titer Filament count Ends per position Mechanical speed Chuck length Volume Spinning beam series Winder type series Quench type series

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10 ends 20 ends 30 - 400 den 30 - 200 den 0.3 - 6.3 dpf 0.5 - 5.0 dpf 12 - 384 18 - 144 10 2 x 10 2500 - 4000 m/min 2500 - 4000 m/min 1500 mm 2 x 1500 mm 16.8 dm³ 16.8 dm³ Extruder or direct spinning SP8x (z) SP8x (z) WINGS 2 x WINGS EvoQuench (z), cross-flow EvoQuench (z), cross-flow

POY solutions – Oerlikon Barmag


© VAUDE

POY solutions – Oerlikon Barmag

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Polyamide 6 POY

The Oerlikon Barmag process for the production of polyamide 6 POY opens up a surprisingly broad denier range. Furthermore, this process is characterized by high productivity and excellent prerequisites for manufacturing polyamide 6 microfibers. The design of the draw unit can very flexibly cover all product areas. And once again the best CV% values and AA-quality yarn are standard here – as in the case of all our processes.

Process Titer final Single filament titer Filament count Ends per position Mechanical speed Chuck length Volume Extruder spinning Spinning beam series Winder type serie Quench type series

20 - 150 den 1.0 - 4.2 dpf 3 - 96 12, 2 x 12 3500 - 4800 m/min 1500 mm 13.0 dm³ SP8x WINGS, 2 x WINGS cross-flow

Polyamide 6.6 POY

Approximately 80% of the world’s yarn producers use Oerlikon Barmag systems for manufacturing polyamide 6.6. This shows to what extent we have mastered the process. Specially designed extruders, spinning units and take-ups for the PA6.6 process permit high productivity and a broad denier range. Hence, this process is also unrestrictedly suitable for the production of PA6.6 microfibers. And – as always – we also guarantee the best CV% values and AA yarn qualities with this process.

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POY solutions – Oerlikon Barmag

Process Titer final Single filament titer Filament count Ends per position Mechanical speed Chuck length Volume Extruder spinning Spinning beam series Winder type series Quench type series

20 - 100 den 1.0 - 4.2 dpf 3 - 96 8 2500 - 4800 m/min 1200 mm 16.8 dm³ SP4x WINGS cross-flow


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Key components First-class solutions comprise first-class machine systems manufactured using first class components. This commitment determines the quality of our components. Oerlikon Barmag’s product range comprises extruders all the way through to the winding systems for all components within a spinning plant. As a systems constructor, we know the importance of the individual process steps and each partial component. For this reason, all Oerlikon Barmag components have their own success story: we have been designing and constructing extruders since 1958, the company has more than 50 years of experience in building pumps and has supplied in excess of 100,000 winders throughout the world since 1972. We are not content with merely tried-and-tested design – our mission statement is the continual further development of all components to achieve even greater efficiency and even better technical solutions for our customers.

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POY solutions – Oerlikon Barmag


The 100,000th winder delivered by Oerlikon Barmag has been goldplated. POY solutions – Oerlikon Barmag

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Extrusion equipment

Oerlikon Barmag spinning extruders excel in gentle and homogeneous melt production and are noted for cost effectiveness, reliability, and long service life. The utilisation of top-quality, low wear materials – in particular for the extruder cylinders and the extruder screw – ensure long-term, error-free operation. The screw geometries with special homogenizing components have been determined to ensure short dwell times, in order to keep the thermal and mechanical loads of the melt to a minimum – the basis for excellent melt and hence first-class yarn quality. Oerlikon Barmag extruders fulfill the energy saving requirements for e-save. The e-save label is given to systems and components that have energy consumptions significantly lower than standard equivalent systems and components available on the market.

Oerlikon Barmag extruders are chracterised by a good barrel insulation resulting in energy savings and a low surface temperature on the barrel jacket. The two-step spur gear guarantees long service life and smooth running. The feed area for inert gas or vacuum is designed to prevent oxidation of the polymer, thus ensuring trouble free spinning. Specially matched screw and barrel materials result in good sliding properties and low wear. Air-cooled extruder series These are the perfect choice for processing PETP, PA6, PA66, PP and other spinning polymers in all viscosity ranges for all man-made fiber requirements. An output ranging from 3 kg/hr to 1,500 kg/hr is possible. This extruder version includes a fine-graduated program with screw diameters from 30 to 175 mm, and screw lengths of 30 L/D or 24 L/D. Further, the specifically-cooled barrel sections expand the production window. The additional feature offered for this series is the control cabinet, which is integrated into the extruder frame. This version transforms our well-established model into a compact unit with significantly less wiring. All versions are available with or without a cooling system for the barrel. An injection system introducing master-batches or liquids into the polymer stream at various locations for customized fiber characteristics is also available.

Throughput capacity 4E

24D PET PA6 PA6.6

norm. kg/h 70 norm. kg/h 40 norm. kg/h 40 4E

30D PET PA6 PA6.6 18

norm. kg/h 90 norm. kg/h 45 norm. kg/h 45

POY solutions – Oerlikon Barmag

6E

7E

9E

10E

12E

15E

17E

130 80 70

200 125 120

300 200 180

400 270 240

520 350 315

820 550 -

1120 750 -

6E

7E

9E

10E

12E

15E

17E

160 90 90

260 145 140

380 230 200

500 310 280

660 400 380

1000 630 -

1380 -


Pumps in a spinning plant

Polymer pumps – for the most demanding requirements Process stability and product quality are heavily influenced by the polymer in the manufacture of man-made fibers. As the leading manufacturer of man-made fiber systems, Oerlikon Barmag knows how the design of the individual systems components influences the quality of the polymer and hence the spinning process. Booster pumps build up the pressure which is required by the system – with a high degree of flexibility and reliability. Booster pumps in polymerization or polycondensation plants, also known as transfer pumps, receive the necessary supply pressure from the discharge pump. These are used to provide the necessary pressure for the downstream consumer units. These consumer units include spinning pumps, flat nozzles, perforated plates for granulation, etc. Frequently, the conditions within the system can also change, for example, through standstill of the downstream units. These demand flexibility; depending on the application even negative differential pressures can occur. Oerlikon Barmag booster pumps solve these tasks thanks to the universally applicable design of the bearing lubrication system. Spinning pumps – innovative and reliable The spinning pump is one of the key components of a spinning system. Even when used over many years of production, all Oerlikon Barmag spinning pumps guarantee consistent yarn quality, the most important factor in successful yarn production. The special advantages of Oerlikon Barmag’s planetary gear spinning pumps include: - optimal melt flow due to rheologically advantageous melt channels - highly polished melt channel surfaces, ensuring superior flow conditions - high-precision manufacturing methods, allowing for excellent running performance and stable melt exchange - specially designed relief grooves in the melt outlet area of the gears, for minimized compression forces and operation with few fluctuations in the flow. Together, these advantages translate into the uniformity of the melt streams.

Spin-finish pumps – high-precision and maintenance-friendly with extreme durability The more even the application of the spin-finish liquid to the yarn, the better the yarn quality. A trailblazing design now sets considerably higher standards in terms of feeding accuracy, reliability and durability. The PROFIN series is designed for use with all commercially available types of spin-finish, from high, down to low oil concentrations. In addition, the production program includes pumps specifically tailored to handle corrosive spin-finish liquids. Identical connection dimensions of the PROFIN spinfinish pumps permit exchange with those of the previous series. PROFIN spin-finish pumps convince by - Long service life - Operator–friendliness - Operating stability - Quality management

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Mixing and metering systems

More than 90% of the world’s textile polyester and nylon filaments are spun in raw-white. Dying the yarns or textiles takes place later in the form of package or piece dyeing despite the fact that these processes are in many respects inefficient. The energy requirements for heating the dye bath and subsequent drying of the dye product – in the case of package dyeing, we must also consider the rewinding – are high. The high consumption of water and chemicals and the associated volume of contaminated waste water have a negative impact on the environment. Furthermore, the dyeing process is time-intensive. e-save with spin-dyeing An alternative is the spin-dyeing of textile and industrial yarns. As the masterbatch is directly added and mixed into the polymer melt, no further process steps are required in the dye plant. The spin-dyeing requires only a fraction of the energy, the water, the processing time and the space needed for conventional dyeing processes.

Additives and dyes for plastics are becoming an increasingly important part of the manufacturing process. The properties of the polymers can be extensively modified as a result of additives. The option of directly introducing these additives during the manufacturing process (e.g. fibers or films) provides a high degree of flexibility and increased efficiency. The dynamic, three-dimensional mixing principle has proven to be an excellent choice when feeding additives, dyes, stabilizers and other polymers. Pumps for liquid additives or compact combination of injection extruders with gear pumps are used for feeding. The systems can be integrated in various areas of the melt system. Powered 3DD mixer One or more additive flows can be added to the main melt flow upstream to the mixer. The constant changing of the rotor/stator groove allocation creates a dynamic 3-dimensional flow that includes both a longitudinal, dispersive and distributive mixing result.

Technical data Powered 3DD mixer Type

Ø (mm)

max. main flow kg/h

7E-3DD 10E-3DD 15E-3DD 17E-3DD 20E-3DD 22E-3DD

75 105 150 175 200 225

260 500 1000 1400 1800 2300

Feed options Additives can be fed into the polymer at various points. The appropriate point must be determined, taking flexibility and costs for each process individually into consideration.

feed position

extruder hopper

upstream to 3DD mixer attached to the extruder

upstream to separatelydriven 3DD mixer

upstream to Promix AC mixer pump

form of additive flexibility costs

granulate 0 ++

melt; liquid additive 0 +

melt; liquid additive + 0

melt; liquid additive ++ 0

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POY solutions – Oerlikon Barmag


Feed extruder with metering pumps These components are required whenever master batch melts need to be metered into the main melt flow under high pressure. Throughput volumes from 3 kg/h can be metered. 3DD mixer as an extruder extension This mixing unit is attached to Oerlikon Barmag extruders as a screw and cylinder extension. The master batches to be added are either fed via the extruder hopper (granulate) or later into the mixing zone (melted up, liquid). The mixing zone can be separately heated or cooled. Powered 3DD mixer as a separate unit This unit is a hot melt extruder with a dynamic mixing function. Here, the pressure differential required for mixing is extensively compensated by the pressure build-up in the screw section. The speed can be selected in accordance with the mixing task. The melt temperature can be influenced by the air-cooled mixing cylinder. The mixer is designed for integration into melt distribution systems for larger throughput volumes (> 100 kg/h). Both melt and liquid mass flows can be fed in. Promix AC For customized feeding of additives or dyes (liquid) at the spinning position, this planetary gear pump offers an injec-

tion function. To this end, the dynamic mixer works synchronous to the pump speed. Pumps with 3, 4, 5, 6, 8, 10 or 12 outlets are available. Promix VS To be able to tend to the mixing and metering functions separately in terms of process, a unit with 2 separate drives for mixing and metering was developed. The unit can be integrated into spinning positions or upstream into the melt distribution system. Inject AC - metering system for liquid additives This system was developed for feeding liquid dyes and additives into plastic granulate (unpressurized) or polymer melt (pressurized). One metering pump is used for unpressurized feeding. When feeding under pressure, two metering pumps in series are used, whereby the first pump carries out the pressure build-up and the second the high-precision metering. The speeds of both pumps are set using an intelligent control system. The system can be completed with pressurized tanks with electrical filling height monitoring and valves. Valve technology enables fast dye changes using a rinse mode.

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Spinning head series SP8x

First-class spinning heads make first-class yarns make first-class profits! The quality of the thread is determined during spinning. The manifold in an Oerlikon Barmag spinning line is specially optimized regarding melt residence time, drop in pressure and shear rate. It is characterized by: - flow-favorable melt distribution for excellent yarn uniformity along the spinning line; - high surface quality of the pipes ensures favorable melt flow behavior for superior quality right from the first day of production; - absolute dead spot-free design is a precondition for low break levels and high yields; - the overall distribution system is virtually maintenancefree.

The SP8x spinning head ensures economic spinning processes with high product quality through its very even melt guidance system with optimized residence time. Furthermore, the shroud – which can be specifically adapted to the respective product on request – ensures an extremely high level of flexibility. The shroud is part of the heat transfer medium (HTM)-heated spinning head and guarantees extremely high temperature evenness without the additional energy requirements of an electrically-heated concept. This system also enables the production of microfilaments without loss of quality and productivity and excellent productivity for standard titers.

Oerlikon Barmag’s spinning head series covers the processes for textile and industrial yarns as well as home textiles even for processing critical materials like PA6.6 and new materials like PTT. In all cases the spinning head steam heating ensures excellent temperature uniformity.

Needless to say, the well-known self-sealing Oerlikon Barmag spin packs can also be used for this system. The rheologically-optimized melt distribution and uniform heating ensures that the good melt quality in the spinning head is also continued within the spin pack.

e-save with SP8x The Oerlikon Barmag SP8x spinning head concept unites the advantages of high-end melt quality. The design of the spinning head has considerably reduced the heat-radiating surface and simultaneously significantly improved the insulation. This has resulted in a more than 40% reduction in the heat-radiation in comparison to the SP5x system. In trials, this has revealed, for example, energy savings of more than 200,000 kWh/year for a 36-position system.

Reduced spacing with zigzag In combination with the EvoQuench radial inflow quenching unit in zigzag layout, the SP8x is also available in a zigzag design. The reduced spacing in comparison to a standard EvoQuench and SP8x spinning head allows for a higher number of spin packs or bigger packs in the same position pitch. This option is available for 88 and 104 mm spin packs.

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Spin packs

Advanced spin pack Through continual further development of the spin packs, the spinneret surface has been increased by up to 25% while maintaining the same external dimensions. The throughput required for the spinning process can hence be achieved with a smaller spin pack diameter. The spinning head melt residence time reduces by 10%. The new design offers the following process benefits: - increased filament distance on spinneret for better filament cooling and fewer yarn breaks, especially for microfiber and high count; - large filter surface for higher throughput, compared to other spin packs with the same outer spin pack diameter; - large filter surface for longer spin pack operation time; - increased filament count (microfiber) compared to other spin packs. The advanced spin pack is available as the proven self sealing version, however, for the production of polyamide 6.6 we supply a forced sealing version.

Double-in-one When looking at throughput, POY systems for small titers require a relatively high level of investment. The 20-fold Double-in-one (DIO) spinning plant concept has been able to considerably reduce the investment costs while maintaining yarn quality. The DIO concept, with two completely-independent spinnerets in one base, allows manufacturers to use approx. 30% less space vis-Ă -vis single packages while retaining the titer evenness. Microfilaments with 20 ends can be efficiently manufactured if the DIO technology is combined with the EvoQuench system. Even yarn specialties can be economically manufactured with the optimal combination of DIO and quenching system. With two independently-operated take-up units and the systematic separation of the respective five DIO spinnerets within the quenching system and spin stack, each position is completely independent of the neighboring position in the same spinning head in the event of yarn breaks. This is evident in the fact that 20-end concepts can achieve full package rates which are the same as those for 10-end processes.

POY solutions – Oerlikon Barmag

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Quenching systems

The main task of the quenching system within the context of complex spinning processes is the even quenching of the liquid filaments at the exit of the spinneret. Oerlikon Barmag quenching systems supply a uniform, turbulence-free airflow for achieving excellent uster values. During the quenching process, each filament is supplied with the same amount of cooling air, hence ensuring defined crystallization and orientation of the polymer molecules as the basis for optimal uster, elongation and dyeability. For this reason, the quenching process has a decisive influence in achieving excellent yarn qualities in the synthetic filament manufacturing process. Moreover, all current processes are covered by this system. Quality assurance down to 0.3 dpf Oerlikon Barmag provides different quenching systems specially matching the customers’ needs: The standard

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POY solutions – Oerlikon Barmag

cross flow quench system is suited for standard yarns higher than 0.5 dpf (denier per filament). The cross flow quench system with quench booster stabilizes the production of yarns in the 0.5 to 1 dpf range. For the production of super fine micro filaments (down to 0.3 dpf) we recommend the EvoQuench system. This allows for a maximum of 388 single filaments per end. 10 ends per position ensure high productivity.


Cross flow quenching system – one unit for (almost) everything This quenching system is the number one choice for all commodity applications. Robust, easy to use, suitable for a broad range of titers and all standard polymers, the Oerlikon Barmag cross flow quenching system feels at home in almost all POY spinning processes. As a result of the specially constructed rectifier, which corresponds to all requirements in terms of even and laminar airflow, extremely high yarn qualities can be achieved. EvoQuench – something innovative from the technology leader In contrast to the cross flow, the air here is symmetrically guided from the outside of the thread bundle to the inside. This ensures optimal flow cooling of the thread along the entire length of the filament surface. The EvoQuench system was developed for micro-fiber yarns all the way down to 0.3 dpf, but also covers a good range of commodity yarns. With more than 3500 installed positions the EvoQuench system is on its way to become a sales hit made by Oerlikon Barmag.

EvoQuench zigzag A spinning system configured with the zigzag version of the EvoQuench quenching unit is extremely compact and simultaneously highly-efficient. When combined with an 88mm spin pack, for example, it can produce ten filaments of outstanding quality on a spinning position of just one meter in width. e-save with EvoQuench In the quenching unit, it is the consumption of controlledprocessed compressed air that is the criterion that determines the resource consumption and hence the conversion costs. Depending on the titer and dpf, Oerlikon Barmag’s EvoQuench unit reduces the air requirements by between 70% and more than 80% compared to a cross-flow quenching unit. The air savings per spinning position add up to more than 20,000 m³ every year.

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On the WINGS of success

WINGS means the integration of all relevant individual components in a conventional POY spinning position within a complete winding unit. More even yarn quality The parallel yarn path achieved with the WINGS concept with its considerably reduced wrapping at the static thread guides results in a minimized wrapping difference between the yarn exterior and interior. While the wrapping difference for conventional POY spinning plants is 28 degrees, WINGS reduces this to only 7 degrees. This guarantees a more even and hence an overall improved yarn quality within a winding position. Close to each other A novel “zigzag” layout enables considerably higher component density for winding positions within the production site as the spinning lines can be assembled in a denser layout. The component density and the lower height of WINGS – the result of dispensing with the operator platform prevalent in conventional POY spinning plants – offers considerable savings potentials for investments in land and buildings. This is a not inconsiderable factor when planning new factories.

At eye level WINGS is at eye level. This means that the yarn can be strung-up by one person – whereby the normal string-up time of 3 minutes is now considerably reduced to 75 seconds and without string-up errors. Clear overview – clear control. Perfect DTY performance WINGS has a reliable ribbon distubring system which takes care of an optimal package construction irrespective of the diameter. Furthermore, the contact pressure control reduces the yarn break rate in the following texturing process by 50 %. Optimized parameters setting avoids expecially bottom breaks. Energy conscious The WINGS concept reduces the energy consumption of the complete spinning system by remarkable 25 to 45 %. This comprises the necessary compressed air, the air conditioning as well as the energy consumption of the drawing zone.

Child’s play WINGS is a plug & play unit. Assembly and commissioning with the completely installed and tested take-up unit are child’s play and can be carried out with minimum cost and time.

Technical data version

Polyester WINGS 40T-1200/8 WINGS 40T-1500/10 Polyamide WINGS 48T-1200/8 WINGS 48T-1500/12

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chuck length mm

tube inner Ø mm

m/min

max. package Ø mm

1200 1500

94 110

2500 - 4000 2500 - 4000

440 440

17.1 / 120

1200 1500

110 125

2500 - 4800 3500 - 4800

440 440

16.8 / 120

POY solutions – Oerlikon Barmag

take-up speed

volume (dm3) / stroke length (mm)

8 ends

10 ends

12 ends

16.8 / 120

13.0 / 95


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Plant Operation Center (POC) The POC – Plant Operation Center – is the all-embracing workflow management system from Oerlikon Textile. It is designed to monitor and optimize the production processes within a production stage, e.g. spinning, or the entire value added chain – starting with the raw material all the way through to the end product. Today, companies are confronted with challenges on all fronts: market requirements are becoming increasingly difficult to plan, pressure on margins is growing and the production environments of dynamic companies are becoming ever more complex. Within companies, data transparency,

The POC creates transparency – the “Job Reports” module The status of manufacturing jobs is graphically displayed at all times per spinning machine and/or per spinning position. The screen shows comparable data of both current and completed jobs. The data is updated with each doff and is, therefore, extremely precise.

The POC increases efficiency – KPI (Key Performance Indicator) in a nutshell The latest addition to the POC gives users the comforting feeling of being informed at all times and in all places. Highlycondensed information on the production systems can be accessed on mobile devices using apps.

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POY solutions – Oerlikon Barmag

integrated processes and efficient resources planning are becoming success factors. The POC connects the production hall with the management and creates the link between the ERP system and the control center. The various POC modules offer you the ideal tools to further increase the productivity and efficiency of your systems. The software is modular, allowing you to create a customized system from the POC modules that is tailored to your precise requirements and that can be expanded at any time.

The POC simplifies the workflow – the “Recipe Management” module Recipes define what shall be produced. They include the complete list of all setpoints or parameters that are important for the product. During production planning, recipes are distributed to the production units.


Downstream process

Texturing – high performance and reliability in harmony As long as there are chemical fibers, there will be the attempt to give smooth man-made fibers a natural fiber-like character. Texturing is a refinement step that transforms POY yarn into attractive and individual products. As early as 1954, Barmag developed the first false-twist texturing machine; today, Oerlikon Barmag is the market leader in this segment with over 1.5 million spindles supplied in more than 7,500 draw-texturing machines.

There is a choice of a wide range of machines to meet every requirement. Whether manual or automatic machine, standard or multi-spindle configuration, each machine fulfils all the expectations which you have of Oerlikon Barmag in points of performance, quality, cost-effectiveness and innovation. The success of our customers is the focal point for Oerlikon Barmag’s development division. Process engineers and those responsible for components place the increase in yarn quality, production speed and flexibility at the centre of their activities.

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SUN – Service UNlimited Getting you to the top What are your expectations when you are deciding on new product ranges and equipment for your textile business? Do you really want to have several providers to manage the complex manufacturing processes you need to control? And can you risk facing the situation that after a few years your investment may be virtually worthless?

Main Oerlikon Textile Service Network Stations plus more than 120 agencies worldwide

We at Oerlikon Textile are convinced that you shouldn‘t accept any of these limitations. This is the reason why Oerlikon Textile has devised SUN – Service UNlimited – the new service initiative that our Customer Support offers with its brands Oerlikon Barmag, Oerlikon Neumag, Oerlikon Schlafhorst and Oerlikon Saurer to all its clients who require more than just service. SUN is a bundle of differentiated services that add real value to your Oerlikon Textile hardware and your daily business in a flexible way. Tailor made services Oerlikon Barmag Service offers you a broad range of products and services to achieve your objectives - faster return on investment, shorter downtimes and process support. Based in Remscheid, a pool of highly qualified employees equipped to react fast and efficiently to the most varied customer demands. From erection and start-up to process consulting – our team of experts is waiting to support you. Moreover, in line with „think globally, act locally“ our worldwide network of service stations will always reach you everywhere. Local repair shops as well as on site workshops at your production plant are characteristic for our service philosophy. Our R&D center at Oerlikon Barmag’s headquarters in Remscheid is equipped with ten modules forming closed, self-sufficient units with a total of ten spinning plants on various levels. Here, customers can test their raw materials and products or develop new applications under optimum overall conditions. All modules can be independently operated in accordance with the respective process requirements. www.myoerlikon.com – access to success The myOerlikon customer portal is up to date at any time, 24 hours a day throughout the whole year. The customer portal has a clearly arranged and uniform home page of all business units and their product lines. Our customers have online access to the latest documentation, tailor made for their machines.

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POY solutions – Oerlikon Barmag

The trouble-shooting manual permits a quicker and more efficient elimination of problems via direct links. The SECOS e-Commerce system, well-known worldwide, is completely integrated. The Engineering tool supports and accompanies the entire engineering process from the concept to the turn-key plant. Innovative ideas and new solutions are added continuously. Latest encryption technology guarantee the maximum data security at any time.


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Oerlikon Barmag Zweigniederlassung der Oerlikon Textile GmbH & Co. KG Leverkuser StraĂ&#x;e 65 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 +1 704 910 42 68 Fax +1 704 910 42 09 info.charlotte@oerlikon.com

The information supplied in this brochure is for guidance only. We reserve the right to modify it at any time.

OBA 204 e / 6/2011 Studio 45 / Koch Subject to changes

Oerlikon Textile Far East Ltd. Room 2806 China Resources Building 26 Harbour Road, 28 / F. Wanchai, HONG KONG P.R.CHINA Phone +852 28 27 43 14 Fax +852 28 27 52 50 info.textile.hk@oerlikon.com Oerlikon Textile India Pvt. Ltd Empire Industries Complex 414, Senapati Bapat Marg Lower Parel (West) Mumbay-400013 INDIA Phone +91 22 6652 7900 Fax +91 22 6652 7901 management.bom@oerlikon.com


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