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Solutions for IDY production


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

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IDY solutions – Oerlikon Barmag

company Oerlikon Barmag’s research 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 1,500 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 headquarters 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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IDY 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 in a spinning plant Spinning head series Spin packs Quenching systems Godets ACW ASW

26 28 30 32 33 34 36 38 40

Plant Operation Center (POC)

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SUN – Service UNlimited

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IDY 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. A harmonized chain of polycondensation, spinning and downstream machines allows efficient production which results in an increase of added value for the customer. We will cater for a harmonization of all machines and lines in an optimal way and will provide the respective know-how. 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. Oerlikon Barmag plant engineering delivers the following services: - feasibility study - consulting services - engineering services - basic and detailed engineering - guarantees for product and production

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IDY solutions – Oerlikon Barmag

Examples for engineering services are: - project management - plant layout and process engineering - machine engineering - electrical and instrumentation engineering - piping engineering Our plant engineering looks after the complete processes, from the polycondensation to coated or dipped fabric 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 our expertise in the challenging field of plant engineering.

Project: PET tire cord with guarantees Location: Belarus Plant type: 3 positions, HMLS extrusion spinning plant, with yarn guarantee Start up: June 2008 Engineering & construction: - Basic engineering - Detailed engineering - Supervision of erection & start up Project: PET industrial yarn with guarantees Location: United Arab Emirates Plant type: 8 positions, PET industrial yarn extrusion spinning plant, with yarn guarantee Start up: 2009 Engineering & construction: - Basic engineering - Detailed engineering - Supervision of erection & start up Project:

PET tire cord and conventional IDY with guarantees Location: Brazil Plant type: 4 x 4 positions, 96-end PET industrial yarn extrusion spinning plant, with yarn guarantee Start up: 2007 Engineering & construction: - Basic engineering - Detailed engineering - Supervision of erection & start up

IDY solutions – Oerlikon Barmag

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IDY spinning solutions

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IDY solutions – Oerlikon Barmag


Tires, safety belts, airbags, coated tarpaulin, MRG, conveyor belts – there are countless uses for the industrial yarns produced on Oerlikon Barmag machines. Correspondingly specific are the demands made on the used yarns. Decades of research and a constant dialog with customers ensure that our systems produce the perfect yarn for each and every application. Flexible With its highly-developed components, know-how and proven technology, our industrial yarn machines manufacture extremely fine yarns all the way through to top-quality coarse yarns (heavy denier) and – depending on the yarn fineness – up to twelve ends per winding position. Our industrial yarn systems are available in several machine configurations: - 4 heated godet duos for hightenacity and low-shrinkage yarns at conventional speeds - 5 heated godet duos for high-tenacity and super-low-shrinkage yarns at conventional speeds - 4 heated godet duos for heavy denier yarns of up to 16,000 den per position at conventional speeds - HMLS godet configuration for polyester tire cord yarn at high speed and - 5 heated godet duos with suitable equipment for high-tenacity and HMLS yarn at high speeds.

Efficient Depending on the process, titer and speed, yarn producers manufacture multiple threads per winding position. This is made quite simple by using Oerlikon Barmag’s industrial yarn systems: our flexible spinning plants are able to draw and wind two, three, four, six, eight or twelve threads simultaneously. Under control All process data – from the extruder through to the winder – are displayed via GUIDE, the Windows-based user interface. The GUIDE system permits total process control: product data management, production statistics, reporting – all this is just a fraction of what GUIDE provides to ensure continual optimization of the production process. In the event of more than one production line, we recommend using the Plant Operation Center (POC), which has an interface to all production lines. SSP, air conditioning and other systems (down-stream), for example can also be integrated.

IDY 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 IDY production systems. Today, they already cause up to a half 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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IDY 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 an IDY spinning system with 8 positions, this generates an annual saving of approx. US$ 89,000. Reducing the consumption of controlled-processed air is an important objective of a radial quenching system. Such a system consumes 60-80% less air than cross-flow quenching – it is available for the production of HMLS yarns with a high number of filaments. Multi-end 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-end filament capability should definitely be considered as an energy-saving factor. Spinning 12-end IDY using one spinning beam with especially designed spin packs, one quenching unit and one draw panel on 2 winders is therefore considerably more efficient than two 6-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.

Saving potential by multi-end technology 12-end IDY spinning compared to 2 x 6-end spinning

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.

IDY 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. Your big advantage is the fact that Oerlikon Textile serves the world’s largest spread of applications in the textile machinery industry. Quality plays a huge role particularly in the industrial yarns sector. These materials are used in all applications where safety is paramount. Tires, safety belts, airbags, climbing harnesses – this is where quality is essential for survival. Therefore, the right partner who has mastered the various processes perfectly is decisive. Technology and support going hand in hand Innovative machines and systems are just part of the story. Our 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 downstream steps in the textile value chain. Oerlikon Barmag’s solutions take a big weight off customers’ minds. Our one-stop shop covers everything from finance through to turn-key plants. Top machinery, comprehensive process skills, professional advice and service are all in the package.

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IDY solutions – Oerlikon Barmag


IDY solutions – Oerlikon Barmag

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Polyester IDY low denier (LDI), high tenacity (HT) and low shrinkage (LS)

High tenacity yarns are predominantly used in manufacturing sewing threads, billboards, sail cloth, luggage cloth and similar items. Low shrinkage (LS) is a particularly important feature in the processing of tarpaulins. The low shrinkage yarns manufactured using our systems have a shrinkage down to 4%, but nevertheless always remain even. It goes without saying that our system configurations come with low conversion costs and energy-efficient components.

Processes Capacity Max. number of ends Denier range

Mechanical speed Chuck length Bobbin stroke x diam. Quench system Winder type series Traverse system

up to 8,000 den per position 16 16 x 250 den** 16 x 500 den** 8 x 750 den* 8 x 1000 den*

2,500-4,000 m/min. 1,600 mm 170 x 360 mm crossflow 1 x ACW or 2 x ACW MST / Birotor

* on one winder ** on two winders 12

IDY solutions – Oerlikon Barmag

up to 2,400 den per position 16 8 x 210 den* 8 x 250 den* 8 x 300 den* 16 x 70 den** 16 x 120 den** 16 x 140 den** 2,500-4,000 m/min. 1,600 mm 170 x 360 mm crossflow 1 x ACW or 2 x ACW MST / Birotor


IDY solutions – Oerlikon Barmag

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Polyester IDY super low shrinkage (SLS)

For applications for which even shrinkage of approximately 4% is too high, fabric manufacturers draw on super-low shrinkage (SLS) yarns. A challenge for all yarn manufacturers – but there is no reason to be nervous with Oerlikon Barmag at your side. The shrinkage of SLS yarns produced on our systems is less than 2.5% (for X-SLS even less than 1.5%). However, those planning to manufacture SLS yarns need not dispense with the high tenacity properties. Our system configurations permit the flexibility to produce either SLS or high tenacity (HT) yarns with one machine layout. Furthermore, our 12,000 den systems are incredibly flexible: from 6-end to 12-end – with just a few adjustments.

Processes Capacity Max. number of ends Denier range

Mechanical speed Chuck length Bobbin stroke x diam. Quench system Winder type series Traverse system

up to 6,000 den per position 6 6 x 500 den 6 x 1,000 den

2,500-4,000 m/min. 1,200 mm 170 x 360 mm crossflow 1 x ACW MST / Birotor

* on one winder 14

IDY solutions – Oerlikon Barmag

up to 6,000 den per position 12 12 x 250 den 12 x 500 den 6 x 500 den* 6 x 1,000 den* 2,500-4,000 m/min. 1,200 mm 170 x 360 mm crossflow 1 x ACW or 2 x ACW MST / Birotor

up to 6,000 den per position 12 12 x 250 den 12 x 500 den 6 x 500 den* 6 x 1,000 den* 2,500-4,000 m/min. 1,200 mm 170 x 360 mm crossflow 1 x ACW or 2 x ACW MST / Birotor

up to 12,000 den per position 8 8 x 1,000 den 8 x 1,500 den 4 x 2,000 den* 4 x 3,000 den* 2,500-4,000 m/min. 1,200 mm 250 x 360 mm crossflow 1 x ACW or 2 x ACW MST / Birotor


IDY solutions – Oerlikon Barmag

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Polyester IDY heavy denier high tenacity (9,000 den)

Heavy denier high tenacity yarns are produced for applications in conveyor belts and other heavy fabrics. Geo-textiles is also a sector with growing potential. Our industrial yarn processes are also perfectly designed for this. Our 9,000 den machines permit interesting configurations. Faster retooling from 3 ends to 6 ends helps yarn manufacturers to flexibly adapt to market demands.

Processes Capacity Max. number of ends Denier range

Mechanical speed Chuck length Bobbin stroke x diam. Quench system Winder type series Traverse system

up to 9,000 den per position 3 3 x 1,500 den 3 x 2,000 den 3 x 3,000 den 2 x 4,000 den 2,500-4,000 m/min. 900 mm 250 x 360 mm crossflow 1 x ACW MST / Birotor

* on one winder

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IDY solutions – Oerlikon Barmag

up to 9,000 den per position 6 6 x 1,000 den 6 x 1,500 den 3 x 2,000 den* 3 x 3,000 den* 2 x 4,000 den* 2,500-4,000 m/min. 900 mm 250 x 360 mm crossflow 2 x ACW MST / Birotor


IDY solutions – Oerlikon Barmag

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Polyester IDY heavy denier high tenacity (12,000 & 16,000 den)

High efficiency is the key feature of the 12,000 den variant in Oerlikon Barmag’s heavy denier, high tenacity program. High output in the smallest of spaces – this is easily achievable with this system configuration. The slightly higher energy consumption permits manufacturers to double their output. A huge advantage in terms of conversion costs.

Processes Capacity Max. number of ends Denier range

Mechanical speed Chuck length Bobbin stroke x diam. Quench system Winder type series Traverse system

up to 12,000 den per position 4 4 x 1,500 den 4 x 2,000 den 4 x 3,000 den 2 x 6,000 den 2,500-4,000 m/min. 1,200 mm 250 x 360 mm crossflow 1 x ACW MST / Birotor

* on one winder

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IDY solutions – Oerlikon Barmag

up to 16,000 den per position 8 8 x 1,000 den 8 x 1,500 den 8 x 2,000 den 4 x 3,000 den* 4 x 4,000 den* 2,500-4,000 m/min. 1,600 mm 250 x 360 mm crossflow 1 x ACW or 2 x ACW MST / Birotor

up to 16,000 den per position 16 16 x 1,000 den 8 x 2,000 den*

2,500-4,000 m/min. 1,600 mm 170 x 360 mm crossflow 1 x ACW or 2 x ACW MST / Birotor


IDY solutions – Oerlikon Barmag

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Tire cord – HMLS Flex for HMLS and HT / LS

HMLS yarns are the stuff that car tires are made of. At least they are predominantly. HMLS yarns made from polyester provide a stable performance at high speeds, which is why this material is unbeatable for most road conditions and speeds. Our HMLS Flex configuration enables flexible retooling for HT/LS yarns, allowing yarn producers to quickly adapt their processes to changing market demands and requirements. And yarns to retool from the production of conveyor belts to tire cord, for example.

Processes Capacity

HMLS 1 up to 4,500 den per position

Max. number of ends Denier range

3 3 x 1,000 den (HMLS) 3 x 1,300 den (HMLS) 2 x 1,500 den (HMLS) 2 x 2,000 den (HMLS) 3 x 1,500 den (HMLS)

Mechanical speed Chuck length Bobbin stroke x diam. Quench system Winder type series Traverse system

up to 7,000 m/min. 900 mm 250 x 360 mm crossflow 1 x ACW MST / Birotor

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IDY solutions – Oerlikon Barmag

HMLS Flex up to 4,500 den (HMLS) up to 6,000 den (HT/LS) per position 3 3 x 1,000 den (HMLS) 3 x 1,300 den (HMLS) 2 x 1,500 den (HMLS) 2 x 2,000 den (HMLS) 3 x 1,500 den (HMLS) 3 x 1,500 den (HT and LS) 3 x 2,000 den (HT and LS) 2 x 3,000 den (HT and LS) up to 7,000 m/min. 900 mm 250 x 360 mm crossflow 1 x ACW MST / Birotor

HMLS 3 up to 6,000 den per position

HMLS 4 up to 6,000 den per position

4 4 x 1,000 den 4 x 1,300 den 4 x 1,500 den 2 x 2,000 den

4 4 x 1,000 den 4 x 1,300 den 4 x 1,500 den 2 x 2,000 den

up to 7,000 m/min. 1,200 mm 250 x 360 mm crossflow 1 x ACW MST / Birotor

up to 7,000 m/min. 1,200 mm 250 x 360 mm radial 1 x ACW MST / Birotor


IDY solutions – Oerlikon Barmag

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Polyamide 6 and 6.6 IDY medium and heavy denier

And we can also equip you for the gravel track: tire cord made from polyamide yarns is – due to its better ductility – more suitable for this application. We will create the optimum configuration for your systems. Furthermore, our polyamide 6 and 6.6 medium and heavy denier processes also offer an extremely broad range of applications. Fishing nets, airbags, sewing yarns – just a small selection of the possibilities. On request, we can also adapt the layout for the production of super-low shrinkage (SLS) yarns.

Processes Capacity

Mechanical speed Chuck length Bobbin stroke x diam.

up to 4,000 den per position 4 4 x 630 den 4 x 840 den 4 x 945 den 2 x 1,260 den 2 x 1,680 den 2 x 1,890 den 2,500-4,000 m/min. 1,200 mm 250 x 360 mm

Quench system Winder type series Traverse system

crossflow 1 x ACW MST / Birotor

Max. number of ends Denier range

* on one winder **on two winders

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IDY solutions – Oerlikon Barmag

up to 6,000 den per position 6 6 x 630 den 6 x 840 den 6 x 945 den 3 x 1,260 den 3 x 1,680 den 3 x 1,890 den 2,500-4,000 m/min. 900, 1,200 mm 170 x 360 mm* 250 x 360 mm** crossflow 1 x ACW or 2 x ACW MST / Birotor

up to 8,000 den per position 8 8 x 630 den 8 x 840 den 8 x 945 den 4 x 1,260 den 4 x 1,680 den 4 x 1,890 den 2,500-4,000 m/min. 1,200, 1,600 mm 170 x 360 mm* 250 x 360 mm** crossflow 1 x ACW or 2 x ACW MST / Birotor


IDY solutions – Oerlikon Barmag

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Polyamide 6 and 6.6 IDY low denier

And we can also get you onto the right track for low denier PA6 and PA6.6 products. Furthermore, we can adapt your system for super-low shrinkage (SLS) yarns as well, if required. Low denier polyamide 6 and 6.6 yarns are particularly sporty: as the basis material for parachute silk, climbing harnesses and ropes – particularly those used in mountaineering – these yarns are often vital to life.

Processes Capacity

Mechanical speed Chuck length Bobbin stroke x diam.

up to 4,000 den per position 6 6 x 210 den 6 x 315 den 6 x 420 den 3 x 420 den 3 x 630 den 3 x 840 den or 6 x 420 den 6 x 630 den 3 x 840 den 3 x 1,260 den 2,500-4,000 m/min. 1,200 mm 170 x 360 mm

Quench system Winder type series Traverse system

crossflow 1 x ACW MST / Birotor

Max. number of ends Denier range

* on one winder **on two winders

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IDY solutions – Oerlikon Barmag

up to 6,000 den per position 8 8 x 210 den 8 x 315 den 8 x 420 den 4 x 630 den 4 x 840 den or 8 x 420 den 8 x 630 den 4 x 840 den 4 x 1,260 den 2,500-4,000 m/min. 1,200, 1,600 mm 170 x 360 mm* 250 x 360 mm** crossflow 1 x ACW or 2 x ACW MST / Birotor


© VAUDE, M. Attenberger IDY solutions – Oerlikon Barmag

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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 80 years of experience in building pumps and has supplied in excess of 92,000 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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IDY solutions – Oerlikon Barmag


IDY 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 utilization 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.

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 manmade fiber requirements. 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.

Oerlikon Barmag extruders are characterized 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.

Throughput capacity 24D PET

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norm.

kg/h

9E

10E

12E

15E

17E

180

245

360

540

720

PA6

norm.

kg/h

160

220

280

440

600

PA6.6

norm.

kg/h

140

200

315

490

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IDY solutions – Oerlikon Barmag


IDY solutions – Oerlikon Barmag

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Pumps in a spinning plant

Planetary melt spinning pumps 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; - melt channels with optimised 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. Rectangular melt spinning pumps are available on request. Planetary spin-finish pumps 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 Oerlikon Barmag spin-finish pump concept is based on the old proven planetary gear pump principle with a centrally driven sun gear and four planetary gears. The balanced force ratio within the pump and the constructively influenced low bearing load guarantee low frictional wear. In addition to its small size with flow paths of equal length, one major benefit is the large number of possible outlets per pump, whereby the maximum number of outlets is 40. Hence, for a spinning plant with a take-up unit for 20 threads, a spin finish pump would suffice for a double spin finish system (oiling system).

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IDY solutions – Oerlikon Barmag

PROFIN Feed accuracy, operating stability, and service life of the equipment are the fundamental properties of our spin-finish pumps. As far as the PROFIN series is concerned, excellent feeding accuracy, optimum internal flow conditions and the self-venting effect which prevents the agglomeration of airbubbles represents preconditions for a precise and uniform oil-application on a high quality standard. Mixing and metering in polymer processing Extremely high metering accuracy and mixing performance ensure that your products are top quality. There is a series of systems available for the various feeding and mixing tasks, optimally designed to fulfill the requirements of flexible production. Colour and additive injection is primarily used with textile filaments. Nevertheless, for producers interested in mixing and metering injection systems are available on request.


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Spinning head series

The quality of the thread is determined during spinning. The spinning components used provide your yarn with its ultimate qualities. Therefore, they are particularly close to the hearts of our engineers. The manifold in an Oerlikon Barmag spinning line is specially optimized regarding melt residence time, drop in viscosity 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. Oerlikon Barmag’s spinning head series covers the processes for textile and industrial yarns as well as home textiles. In all cases the spinning head steam heating ensures excellent temperature uniformity.

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. 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 dowtherm-heated spinning head and guarantees extremely high temperature evenness without the additional energy requirements of an electrically-heated concept. 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.

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IDY solutions – Oerlikon Barmag


Spin packs

All polymers place different demands on spin packs. The broad Oerlikon Barmag portfolio contains the suitable type for each and every raw material, optimized in terms of their rheological features of the melt-liquid polymers. Our range of spin packs caters perfectly to the product diversity of industrial yarns. Quick and easy retooling makes them compatible amongst each other. The filter media are predominantly metal fabrics and filter sands (quartz sands, metal powders, ceramic powders). Oerlikon Barmag spin packs are available with diameters of 135, 145, 165, 172 or 260 mm. Filter fabrics made from metal 3LA The metal fabric, commonly known as 3LA filter and which has meanwhile established itself on a global scale, is one of the most important IDY spin pack innovations. Its excellent properties - up to 5 times larger filter area compared to standard sand pack; - reusable filter candles; - longer life time; - almost constant pack pressure over operation time;

- outstanding evenness of polymer flow without dead spots; - easy handling ensuring constant process behavior and avoiding improper assembly; - identical filtration conditions from position to position; - reduced operating costs and yarn breaks; - exchangability with standard sand packs; - ideal for the hydraulic split technology clearly underline the superiority of the 3LA spin pack. For this reason, the 3LA spin pack is also standard in polyester and polyamide 6 spinning systems in Oerlikon Barmag plants.

Filter sands An alternative is, of course, the well-established filter methods using sand-like aggregates. Catering to the special features of PA6.6 when subjected to heat requires the use of quartz sands, metal powders or ceramic powders. Needless to say, these filter media with the Oerlikon Barmag packaging system are also suitable for other materials such as polyester, polyamide 6 and polypropylene, to name but a few.

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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. Our quenching systems supply a uniform, turbulence-free airflow for achieving excellent yarn uniformity. During the quenching process, each filament bundle is supplied with the same amount of cooling air, hence ensuring defined crystallization and orientation of the molecular polymer structure as the basis for the optimal physical properties, 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, e.g. PET, PA 6, PA6.6 and others.

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IDY solutions – Oerlikon Barmag


Crossflow quenching system The crossflow quenching system excels in terms of its extremely uniform flow profile for even filament quality and thus highest evenness and performance. User-friendliness, in addition to the quality, is a further important criterion in the design of our systems and is also guaranteed in the case of Oerlikon Barmag’s industrial yarn systems: the crossflow quenching is characterized by simple maintenance and remarkably easy access to the spinning heads.

Radial quenching system The efficiency of the system is high, even with large throughput volumes. Due to the uniform physical properties of the individual filaments, this is the quenching principle to achieve outstanding yarn quality. For HMLS processes with a high number of filaments the radial quenching system is an option. Its major advantage in terms of preserving natural resources is the extremely low air consumption.

IDY solutions – Oerlikon Barmag

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Godets

Oerlikon Barmag godets are custom-developed components for manmade fiber production. Continual innovations in the areas of design, process, and safety fulfill the everincreasing demands of ever faster processes. Our godet families are renowned for their countless productive details. Their process technological properties make it possible to achieve outstanding results in a huge variety of processes.

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IDY solutions – Oerlikon Barmag


High productivity and competitiveness are ensured thanks to the following basic requirements: - robust design; - achievable process speeds; - low operating cost; - reduced maintenance times; - the suitable godets for all manmade fiber processes.

requirements for the e-save label. The energy savings are, independent of the increasing number of yarn ends per position, more than 1 kW per godet. Lower energy consumption also reduces investment in a large-scale A/C system, power distribution units, etc. The power management ensures that the individual take-up positions are not required to provide maximum output.

HF godets To fulfill the special demands made on godets in industrial yarn spinning processes – significant drawing and shrinkage forces plus utmost uniform temperature profiles – our godets have been optimized both for conventional industrial yarn processes and HMLS processes. The HF godet speeds range from 350 – 7,000 m/min. High-speed bearings with long service lives, using the Barolub lubrication system, and low power consumption tailored to the latest industrial yarn processes up to 16 ends with a denier range of up to 16,000 den per position, are further benefits.

Digital control for user-guided operation All godet families are integrated in an interconnected control and drive system. The asynchronous motors are individually speed controlled by digital frequency inverters with heated HF godets. The temperature control of the multi-zone heaters is also operated digitally. This guarantees an extremely easy, time-saving menu-controlled operation.

Our systems support the following industrial yarn processes: - HT (high tenacity); - SHT (super high tenacity); - LS (low shrinkage); - SLS and X-SLS (super-low shrinkage); - HMLS and Flex (high modulus, low shrinkage); - HT (heavy denier up to 16,000 den per position). Lower energy consumption Compared to other godet heating concepts, the HF principal has 20% less power consumption than, for example, 50Hz heat pipe systems. The HF godet family thus easily fulfills the

Economic maintenance Extended maintenance cycles result in higher machine efficiency and increased productivity for the customer. Of special benefit are the easy machine assembly/disassembly with the aid of flange mountings, plug-in connections, as well as a decrease of individual parts by 50%. This results in a significant reduction in maintenance costs. Dependable quality at high output rates Stable operation, even at highest process speeds, is guaranteed by a fail-safe design principle and components that are uncompromising with regard to safety. This includes solid steel shells with no built-in parts as well as the drive motor and speed monitoring.

Technical data R220-400V60

HFO220-400V60 HFO220-400V70 HFP250-535V70 HFP250-535V45

speed

[m/min] 350 - 6,000

350 - 6,000

350 - 7,000

400 - 7,000

400 - 4,500

diameter

[mm]

220

220

220

250

250

length

[mm]

400

400

400

535

535

250

250

260

260

temperature max. [°C] installed heating capacity

[kW]

lubrication draw force

[N]

4x4

4x6

8x4

8x6

Barolub

Barolub

Barolub

Barolub

Barolub

max. 75

max. 75

max. 138

max. 174

max. 320

IDY solutions – Oerlikon Barmag

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ACW

Suitable for all fiber applications – whether POY, FDY, HOY or industrial yarn – our winders offer a high level of flexibility and profitability. Their wide operation window makes them a reasonable investment. The ACW winder makes it possible – with two winders – to wind up to 2 x 8 ends per position. Depending on the necessary package weight, the ACW winder series is suitable for manufacturing in the small, medium and high denier ranges, which are required for industrial yarns. To increase machine productivity, also for the small and medium denier ranges, the machine can be set up for simultaneous manufacturing of 16 ends. Yarn quality Packages wound using the ACW are of better quality. The full package protection feature ensures lint-free packages. An improved take-off in further processing is guaranteed as a result of the possibility of varying the contact pressure along the entire length of the package.

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IDY solutions – Oerlikon Barmag

The hybrid bearing is designed for lifetime lubrication. Dispensing with oil mist lubrication ensures a more pleasant working environment for the operator: soiling of the machine, the yarn and the package are kept to a minimum. A sensor-controlled transfer tail device guarantees 100% uniformity for the transfer and the end locator bunch. As a result of the electrically driven bailor rolls, the shape of the packages can be influenced, hence enabling a qualitatively specified further processing.


Efficient operating The extended parking time allows more relaxed doffing, as the time window in which doffing has to be carried out has been considerably expanded. And the designers have also taken the operator into consideration in the development of the new ACW: the noise level has been significantly reduced with the BIROTOR / multi stroke traverse motion unit (MST). The service interface, positioned on the front of the winder, has noticeably increased the maintenance-friendliness for service staff. The semi-automatic string-up device simplifies the string-up process for the operator, hence improving efficiency.

Cost advantages Electrical chuck brakes offer yarn manufacturers various advantages: reduced energy consumption and non-wear – and hence maintenance-free – brakes. Soiling of the final products caused by brake dust is now a thing of the past.

Design Smooth surfaces and the carefully considered layout of the components ensure that the ACW is a maintenance-friendly, easy-to-clean unit. The positioning of the electronic control unit – conceived as a plug-in component – makes the ACW approx. 25% shorter than other standard winders. Furthermore, the position of the control unit means the ACW does not require air-conditioning behind the take-up head.

Technical data Version chuck length / ends

max. speed

denier range / yarn end

max. denier / tube winder inner Ø

package max. Ø

mm / ( )

m/min.

den / final

den / final

(mm)

(mm)

ACW-4IY 1200/4 ACW-4TI 1200/6 ACW-4IY 1600/8 ACW-4TI 1600/8 ACW-4IY 900/3 ACW-7IY 900/3 ACW-7IY 1200/4

2,500-4,000 2,500-4,000 2,500-4,000 2,500-4,000 2,500-4,000 2,500-7,000 2,500-6,600

1,000-6,000 200-1,500 1,000-4,000 200-1,500 1,500-4,000 1,000-2,000 1,000-2,000

12,000 6,000 16,000 12,000 9,000 4,500 6,000

94 94 125 125 94 110 110

360 360 360 360 360 360 360

ends (x) stroke length (mm) volume (dm3)

4 x 250 / 23.2 6 x 170 / 15.7 8 x 170 / 14.7 8 x 170 / 14.7 8 x 170 / 14.7 3 x 250 / 22.4 4 x 250 / 22.4 IDY solutions – Oerlikon Barmag

39


ASW

With the groove roller to the perfect package – the fully automatic ASW winder is an alternative for industrial yarn and tire cord. Especially for airbag yarn the ASW is the first choice. These winders are characterized, thanks to their groove roller traverse system, by an excellent package build. Yarn tensions arising between the spinning nozzle and the winder are well balanced by the groove roller. There is a total of three different chuck lengths of 600 mm, 920 mm and 1,200 mm available for the ASW. The maximum speed of the ASW winders is currently 5,000 m/min. The threads are treated very gently by means of a special chuck movement during the change process. This makes it possible to use the winder even for very sensitive yarns.

Technical data ASW 600 / ASW 920

ASW 1200

40

version

chuck length (mm)

tube inner Ø (mm)

take-up speed (m/min)

max. package Ø (mm)

volume (dm³) / tube length stroke length (mm) (mm)

602 603 604 923 924 926

600 600 600 920 920 920

75 / 94 75 / 94 75 / 94 94 94 94

1,500 - 5,000 1,500 - 5,000 1,500 - 5,000 2,500 - 5,000 2,500 - 5,000 2,500 - 5,000

420 420 420 420 420 420

32 / 250 22 / 170 16 / 120 32 / 250 24 / 190 16 / 120

version

chuck length (mm)

tube inner Ø (mm)

take-up speed (m/min)

max. package Ø (mm)

volume (dm³) / tube length stroke length (mm) (mm)

1204 1206 1208

1,200 1,200 1,200

94 / 110 94 / 110 94 / 110

2,500 - 5,000 2,500 - 5,000 2,500 - 5,000

420 420 420

32 / 250 22 / 170 16 / 120

IDY solutions – Oerlikon Barmag

300 200 150 306.6 230 153.3

300 200 150


Plant Operation Center (POC) POC – Plant Operation Center – is the all-embracing workflow management system from Oerlikon Textile. It is designed to detect and optimize the production processes within a production stage, e.g. spinning, or over all production stages – starting with the raw material up to the end product.

Advanced features Job disposition Production jobs are presented either as an ERP form or via the ERP interface. Production jobs are distributed as manufacturing jobs to fixed or specifically configured production units, i.e. they are planned.

At the same time, Oerlikon Textile is extending POC with a view to integrating all levels of internal order handling. Thanks to a high degree of modularity, scalability, and system openness with POC, Oerlikon Textile can offer customers a perfectly tailored solution enabling a simple start and including the possibility of continuous upgrading.

Manufacturing jobs or partial manufacturing jobs are defined by the number of packages (weight), the running length categories, and perhaps the qualities. Job view The status of manufacturing jobs and partial manufacturing jobs is displayed at any time. The screen shows comparable data of the planned job as well as of the actual job. The data are updated with each doff and therefore, are very precise.

IDY solutions – Oerlikon Barmag

41


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, selfsufficient units with a total of ten spinning plants on various levels. All modules can be independently operated in accordance with the respective process requirements. The texturing R&D center at Oerlikon Barmag’s texturing equipment hub in Suzhou provides all currently available Oerlikon Barmag draw texturing machine types as well as facilities to evaluate process and machine performance supported by our experienced team of engineers. At both locations customers can test their raw materials and products or develop new applications under optimum overall conditions. 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

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IDY solutions – Oerlikon Barmag

business units and their product lines. Our customers have online access to the latest documentation, tailor made for their machines. 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 guarantees the maximum data security at any time.


IDY solutions – Oerlikon Barmag

43


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 208 e / 6/2010 Studio 45 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


OBA_208_Industrial_yarn.pdf