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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 company Oerlikon Barmag’s research

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IDY 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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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 Melt preparation Pumps in a spinning plant Spinning head series Spin packs Quenching systems Godets ACW

24 26 27 28 29 30 32 34

Plant Operation Center (POC)

36

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 poly-condensation, spinning and downstream machines allows efficient production which results in an increase of added value for the customer. We ensure the harmonization of all machines and lines in an optimum manner, providing our customers with the respective know-how. In plant engineering and construction, the term plant design means turnkey construction. This means that – from the feasibility study all the way through to the implementation of projects – customers receive all services from a single source. Oerlikon Barmag plant engineering delivers the following services: - Feasibility study; - Consulting services; - Engineering services; - Plant layout; - Basic and detail engineering; - Procurement, expediting and inspection; - Process know-how and technology;

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IDY solutions – Oerlikon Barmag

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Guarantees for product and production; Supervision of erection and start-up; Operator training; Site management.

Examples of engineering services are: - Project management; - Plant layout and process engineering; - Mechanical engineering; - DCS, electrical and instrumentation engineering; - PCS engineering; - Piping engineering; - Energy and utilities engineering; - Data and technical documentation; - Operating instructions. Our plant engineering looks after the complete processes, from the poly-condensation to coated and 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 conjunction with cutting-edge technology and a comprehensive global service offering, engineering meets customer demand for a total solution from a single source. A selection of projects demonstrates our expertise in the challenging field of plant engineering. Project: PET tire cord Location: Belarus Plant type: 3 positions, HMLS extrusion spinning plant, with yarn process guarantees Start-up: June 2008 Scope of supply: - Chip conveying & storage - Chip drying unit - Extruder, spinning, take-up and accessories Project: PET industrial yarn Location: United Arab Emirates Plant type: 8 positions, PET industrial yarn extrusion spinning plant, with yarn process guarantees Start-up: 2009

Scope of delivery: - SSPC - Chip conveying, storage - Chip crystallization and drying - Extruder, spinning and take-up - Quench air and take-up air conditioning system - Utility generation - Accessories such as mechanical workshop - Chemical and textile laboratory Project: PET tire cord and industrial yarn Location: Brazil Plant type: 4 x 4 positions, industrial yarn extrusion spinning plant, with yarn process guarantees Start-up: 2007 Scope of delivery: - Chip conveying, storage - Extruder, spinning and take-up - Quench air and take-up air conditioning units - Utility generation - Accessories such as spinneret cleaning system, chemical and textile laboratory Project: PET industrial yarn Location: Spain Plant type: 2 + 2 positions, PET industrial yarn extrusion spinning plant, with yarn process guarantees Start-up: April 2010 Extension: Start-up July 2011 Scope of delivery: - Chip conveying, storage - Extruder, spinning and take-up - Quench air and take-up air conditioning units - Accessories Project: PET industrial yarn Location: Brazil Plant type: 3 x 4 Positions, PET industrial yarn extrusion spinning plant, with yarn process guarantees Start-up: 2012 Scope of delivery: - Chip drying, conveying, storage - Extruder, spinning and take-up - Quench air and take-up air conditioning system - Utility generation - Chemical and textile laboratory

IDY solutions – Oerlikon Barmag

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IDY spinning solutions

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IDY solutions – Oerlikon Barmag


Tires, safety belts, airbags, coated tarpaulins, conveyor belts – there are countless applications for industrial yarns manufactured 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 and – depending on the yarn fineness – up to 24 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 PET heavy denier yarns of up to 18,000 den per position at conventional speeds - 5 heated godet duo HMLS configuration for polyester tire cord yarn at high speed, also suitable for HT/LS yarn - 4 heated duo low denier IDY lines for 24 ends - 2 heated duo low denier IDY lines for medium tenacity 24 ends - 5 heated godet duo safety yarn concept for PET seat belt and PET air bag yarn.

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 four, six, eight, twelve, 16 or 24 threads simultaneously. Under control All process data – from the spinning 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. Air conditioning and other systems (down-stream), for example can also be integrated.

All listed PET concepts can also be operated with direct spinning processes. Here, Oerlikon Barmag can supply the link to the melt finisher. Reference machines are already in operation.

IDY solutions – Oerlikon Barmag

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e-save – energy saving and more Think e-save and reduce your production costs! This is the motto under which 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 enables 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 are already responsible for 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 location 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. 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. The influence of godets on the energy efficiency of a spinning system is also remarkable. The main effect of the HF godet technology is that the energy is only fed to the shell of the godet itself, the only part of the godet that actually needs to be heated. With the standard 50-Hz heating technology, this skin effect is negligible. For this reason, the 50-Hz heater needs at least 20% more energy which results from the power loss caused by heat distribution in the heater tube, the shaft and the front of the shell.

signed spin packs, one quenching unit and one draw panel on two winders is therefore considerably more efficient than two 8- or 12-end spinning positions. A decisive associated factor influencing the overall energy consumption is the air-conditioning system. Drives, heating systems, components that come into contact with the melt and 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. Furthermore, water-cooled godets and electrics generate a further reduction of the heat load within the take-up area. 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.

Another advantage of the HF technology is the fast heat-up caused by the direct energy transfer, meaning that Barmag godets react extremely fast to changes. 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 16- or 24-end IDY using one spinning beam with especially de-

Saving potential by multi-end technology One position with 16-ends spinning compared to two positions with each 8-ends spinning

IDY solutions – Oerlikon Barmag

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Process solutions

Our customers benefit from the comprehensive optimization of individual processes along the textile value chain. Your big advantage is the fact that Oerlikon Textile serves the world’s largest range 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 go hand-in-hand Innovative machines and systems are just part of the story. Our solutions turn machines into teams. They integrate production processes and harmonize every item of equipment perfectly with the next. Customers profit from Oerlikon Barmag’s comprehensive process know-how along the poly-condensation, 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 HT/LS (High-Tenacity / Low-Shrinkage) concept

High-tenacity yarns are produced for applications in conveyor belts and other heavy fabrics. Another application sector with huge growing potential is Geotextiles. The high-tenacity, highmodulus and low-creep properties typically required for this application to keep soil and rocks in place can be perfectly achieved with our IDY high-tenacity yarn lines.

High efficiency is the key feature of our concepts offering a product range of up to 18,000 den per position. High output per position is easily achievable with this system configuration. A huge advantage in terms of conversion costs. Furthermore, our systems are incredibly flexible: from 6-end or 8-ends to 12-end or 16-ends – with just a few adjustments.

Low-shrinkage is a particularly important feature in the processing of tarpaulins. The Low-Shrinkage (LS) yarns manufactured using this system have a shrinkage of only 4%, but The HT/LS machine concept can also be equipped with a nevertheless always remain even. system for manufacturing adhesive-activated yarns.

Technical data Process

PET HT / LS

ends

4/8

6/12

8/16

denier range (up to)

8 X 1500 4 X 3000 2 X 6000

12 X 1500 6 X 2000

16 X 1000 8 X 2000 4 X 4000

Winder Type

ACW4IY-1200/4

ACW4IY-1200/6

ACW4IY-1600/8 ACW4IY-1200/4

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IDY solutions – Oerlikon Barmag


IDY solutions – Oerlikon Barmag

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Polyester IDY X-SLS concept (X-tra Super-Low-Shrinkage)

For applications for which even shrinkage of approximately 4% is too high, fabric manufacturers require X-SLS Extra Super-Low-Shrinkage yarns. A challenge for all yarn manufacturers – but there is no reason to be nervous with Oerlikon Barmag at your side. The shrinkage of X-SLS yarns produced on our systems can be lower than 1.5%. However, those planning to manufacture X-SLS yarns need not dispense with the high tenacity properties. Our system configurations permit the flexibility to produce either SuperLow Shrinkage (SLS) yarns with less than 2.5% shrinkage, X-SLS yarn with less than 1.5% or high-tenacity (HT) yarn

with one machine layout. Furthermore, our systems are incredibly flexible: from 6 ends or 8 ends to 12 ends or 16 ends – with just a few adjustments. And a total denier range up to 16,000 den offers an outstanding productivity per position. The perfect yarn uniformity maximizes the fabric uniformity after coating. These kinds of X-SLS yarns can even replace yarns previously manufactured in a two-step process.

Technical data Process

PET X-SLS

ends

4/8

6/12

8/16

denier range (up to)

8 X 1500 4 X 3000

12 X 1000 6 X 2000

16 X 1000 8 X 2000

Winder Type

ACW4IY-1200/4

ACW4IY-1200/6

ACW4IY-1600/8

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IDY solutions – Oerlikon Barmag


IDY solutions – Oerlikon Barmag

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Polyester IDY HMLS (High-Modulus Low-Shrinkage)

HMLS yarns are the product that not only car tires but also V belts, conveyor belts, marine ropes and hoses are made of. The benefit of this yarn – manufactured on Oerlikon Barmag lines – is the high dimensional and thermal stability combined with a high tenacity and high modulus. This finally leads to a reduced amount of yarn required for the same final product properties. For tire cord – as one of the main applications for PET HMLS yarns – the carcass determines the load-carrying capacity, the comfort of the tire and the dynamic behavior.

Technical data Process

PET HMLS

ends

4/2

denier range (up to)

4 X 1500 2 X 3000

Winder Type

ACW7IY-1200/4

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IDY solutions – Oerlikon Barmag

The process range of the Oerlikon Barmag line allows a wellbalanced strength-to-elasticity ratio under all circumstances. The Barmag HMLS concept has been engineered to produce a high performance yarn for various technical applications but also be flexibly convertible to run HT/LS yarns, allowing yarn manufacturers to quickly adapt their processes to changing market demands and requirements.


IDY solutions – Oerlikon Barmag

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Polyester safety yarn (seat belt and polyester airbag)

Polyester filaments are offered at approx. 40-50% of the price of comparable polyamide filaments and are therefore becoming increasingly interesting as the material for airbag yarns. With the first commercial application in curtain airbags, this transition has just begun and is now expanding fast within Europe and the US markets. The Oerlikon Barmag safety yarn concept is also well prepared for this development. The special 8-end take-up design was engineered for the production of high dpf seat belt yarn with high-tenacity and non-break filaments, but also

Technical data Process

PET Safety Yarn

ends

8/4

denier range (up to)

8 X 500 8 X 1500 4 X 2000

Winder Type

ACW4IY-1600/8 ACW4IY-1200/4

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IDY solutions – Oerlikon Barmag

reveals its full potential for the high-quality demands in lower deniers that are used in the production of airbag yarns, for example. The Single Filament Layer (SFL) – patent pending – technology ensures an extremely gentle yarn path and a very uniform heating of the filaments using the SFL concept. This is the key factor for uniform dye take-up.


IDY solutions – Oerlikon Barmag

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Polyester Low Denier IDY (LDI) Yarn

Oerlikon Barmag’s systems for low denier industrial yarn cover the full range of high-quality, low-denier filaments, enabling customers to cover a wide variety of luggage, sewing and embroidery applications. The layout with 24 ends per position is the perfect solution for optimizing quality, performance and production costs.

Technical data Process

PET LDI

ends

24

denier range (up to)

24 X 250 24 X 500

Winder Type

ACW4IY-1500/12

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IDY solutions – Oerlikon Barmag


IDY solutions – Oerlikon Barmag

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Polyamide yarn concepts

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 have the optimum configuration for your specific demands. Furthermore, our polyamide 6 and 6.6 processes also offer an extremely broad range of applications. Airbags, conveyor belts, sewing yarns, special safety clothing, sail cloth as well as fishing nets – just a small selection of the possibilities. On the other side, low-denier polyamide 6 and 6.6 yarns are particularly suitable for sports applications: as the base material for parachute silk, climbing harnesses and ropes – specifically those used in mountaineering – these yarns are often vital to life. On request, we can also adapt the layout for the production of Super-Low-Shrinkage (SLS) yarns.

Technical data Process

PA

ends

6/3

8/4

denier range (up to)

6 X 420 6 X 700

8 X 420 8 X 700 8 X 1260 4 X 1680

Winder Type

ACW4IY-1200/6 ACW4IY-900/3

ACW4IY-1600/8 ACW4IY-1200/4

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IDY solutions – Oerlikon Barmag


© 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 nearly 90 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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IDY solutions – Oerlikon Barmag


IDY solutions – Oerlikon Barmag

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Melt preparation

Extrusion equipment Oerlikon Barmag spinning extruders excel at gentle and homogeneous melt production and are noted for cost effectiveness, reliability, and long service life.

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 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 engineered 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.

An optional feature offered 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.

Oerlikon Barmag extruders fulfill the e-save energy saving requirements. The e-save label is awarded to systems and components that have energy consumptions significantly lower than standard equivalent systems and components available on the market. Oerlikon Barmag extruders are characterized by their excellent 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.

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IDY solutions – Oerlikon Barmag

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. The extruder series ranges from 90-mm to 175-mm screw diameter and a throughput range from 40 kg/h to 720 kg/h. Direct spinning Cost competition in the IDY sector is also increasing. Therefore, especially for high capacity installations/plants, the direct spinning technology is becoming more and more attractive. Some of the latest Oerlikon Barmag IDY lines are already operating successfully in a direct spinning process of this kind. For this technology, Oerlikon Barmag can engineer, design and provide the complete system for high IV melt distribution.


Pumps in a spinning plant

Booster pumps Booster pumps build up the pressure required by the system – with a high degree of flexibility and reliability. Booster pumps in polymerization or poly-condensation 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. 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: - Optimum melt flow due to rheologically-advantageous melt channels; - Melt channels with optimized 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 balanced force ratio within the pump and the constructively-influenced low bearing load guarantee low frictional wear. 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 air-bubbles – are the preconditions for precise, uniform and high-quality oil-application. 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. Color and additive injection is primarily used with textile filaments. Nevertheless, injection systems are available on request for producers interested in mixing and metering.

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.

IDY solutions – Oerlikon Barmag

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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 speciallyoptimized in terms of 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 – from the very 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. For all applications, the spinning head vapor heating ensures excellent temperature uniformity.

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IDY solutions – Oerlikon Barmag

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 SP4x 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. 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 ensure that the excellent melt quality in the spinning head is also continued within the spin pack.


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 the 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 3LA or screen filter and metal powders. Oerlikon Barmag spin packs are available with diameters of 104, 120, 135, 145, 165, 172 or 260 mm. 3LA filters The metal filter fabric, commonly known as 3LA filter, which has meanwhile established itself on a global scale, is one of the most important IDY spin pack innovations. Its excellent properties - Outstanding evenness of polymer flow without dead spots; - Up to 5 times larger filter area compared to flat filter screens; - Reusable filter candles; - Longer life time; - Almost constant pack pressure over operation time; - Easy handling, ensuring constant process behavior and avoiding improper assembly; - Identical filtration conditions from position to position; - Reduced operating costs and yarn breaks; - Exchangeability with standard packs;

Needless to say, these filter media with the Oerlikon Barmag spin packs are also suitable for other materials such as polyester, polyamide 6 and polypropylene, to name but a few. Multi end spin packs The multi-end spin packs with two yarn ends out of one body are available for low-denier IDY lines basing on the well-established DIO pack principle or for the higher-denier IDY lines in our new 6LA design. The basic design principle for both concepts is: - Two spin packs in one body; - One pump outlet per end; - Two separated melt streams; - No hydraulic split -> Low den CV. This all result in lower space requirements compared to single-end spin-packs with a similar performance. This technology is the basis of our multi-end IDY processes with 12, 16 or 24-end take-up. The new 6LA principle is based on the well-proven Oerlikon Barmag 3LA filtration and now offers the same advantages such as outstanding evenness, high filtration area, long lifetime, good filter efficiency and reusable filters in a multi-end spin pack.

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.

IDY 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. 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 and yarn path.

Radial quenching system Radial quenching systems offer a very uniform quenching of the filament bundle ensuring a significantly improved single filament quality compared to X-flow. 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 ever increasing demands of ever faster processes and higher denier processes. Our godet families are renowned for their countless productive details. Their technological properties make it possible to achieve outstanding results in a huge variety of processes. High productivity and competitiveness are ensured thanks to the following basic requirements: - Robust design; - Achievable high process speeds; - Low-energy consumption for HF godets; - Reduced maintenance times; This all makes the Oerlikon Barmag godet family the suitable choice for all manmade fiber processes.

processes and HMLS processes. The modular godet series is tailored to the latest industrial yarn processes and covers all possible product ranges up to 24 ends or a denier range up to 18,000 den per position. With these components, every take-up is tailored to the customer’s demands. High-speed bearings with long service lives, using the Barolub lubrication system, and low power consumption are further benefits.

Cold Rolls With the increasing amount of yarn ends per position, a smooth yarn path is becoming more and more important. To ensure a proper pretension of the yarn, the Oerlikon Barmag take-up for more than 6 ends uses a cold roll duo with 220mm diameter.

Lower energy consumption Compared to other godet heating concepts, the HF principal has 20% lower power consumption than 50-Hz heat pipe systems. This results from the skin effect, which directly takes the energy to the location that has to be heated. Furthermore, the HF technology allows a significantly more compact godet design. For the same power output, the godet shell diameter can be reduced by 40 mm.

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

For this reason, the HF godet family easily fulfills the requirements of the e-save label. The energy savings reach 20-30%, even with high numbers of yarn ends per position. Lower energy consumption also reduces the investment in the A/C system, power distribution units, etc. This is further-

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IDY solutions – Oerlikon Barmag


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. The temperature control of the multizone heaters is also operated digitally. This guarantees an extremely easy, time-saving menu-controlled operation. Economic maintenance Extended maintenance cycles result in higher machine efficiency and increased productivity for the customer. Special benefits include the easy machine assembly/disassembly with the aid of flange mountings, plug-in connections and 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. more supported by the power management, which ensures a uniform distribution of the maximum energy load at startup of a take-up position. With the lower heat loss of godets plus the water-cooled electrical control system, the power consumption in the A/C system can also be significantly reduced.

The robustness of the latest bearing arrangement is specifically designed for ultra-high forces and bearing load to achieve the max. lifetime and reliability of the hardware.

Technical data R220400V60

HFO220400V60

HFO220400V70

HFP250535V45

HFP250535V70

speed

[m/min]

350 - 6,000

350 - 6,000

350 - 7,000

400 - 4,500

400 - 7,000

diameter

[mm]

220

220

220

250

250

length

[mm]

400

400

400

535

535

temperature max.

[°C]

–

250

250

260

260

IDY solutions – Oerlikon Barmag

33


ACW

Especially designed for industrial yarn applications, our winders offer a high level of flexibility and profitability. Their wide operation window and robust design makes them a reasonable investment.

The ACW winder makes it possible – with two winders – to wind up to 2 x 12 ends per position. Depending on the necessary package weight, the ACW winder series is suitable for manufacturing in the low-, medium- and high-denier ranges, which are required for industrial yarns. For example, the lowdenier IDY winders cover a product range from 50 to 600 den, while the high-denier winders cover a range from 200 den to 6,000 den per end. Yarn quality Packages wound using the ACW are of excellent quality. The full package protection feature ensures fluff-free packages. A high quality take-off in downstream processing is guaranteed as a result of the possibility of varying the

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IDY solutions – Oerlikon Barmag

contact pressure along the entire length of the package as well as the perfect package build up by the Helicont system and step precision winding programs tailored for the specific denier ranges. As a result of the electrically driven bailer rolls, the shape of the packages can be influenced, hence enabling a high quality level in downstream processing. All yarn guiding elements are designed with the latest low friction surfaces ensuring the highest yarn quality level. A sensorcontrolled transfer tail device guarantees 100% uniformity of the transfer and the end locator bunch.


Efficient operating The extended parking time diameter up to 210 mm allows more relaxed doffing, as the time window in which doffing has to be carried out has been considerably expanded. In the development of the new ACW: the designers have also taken the operator into consideration; the noise level has been significantly reduced with the BIROTOR / multi stroke traverse motion unit (MST).

Design The ACW IDY winder series is specially designed for the high demands of the industrial yarn process. The increasing requirements for higher deniers and better yarn strength currently do not permit the use of a simple upgraded textile winder in industrial yarn processes. For this reason, the ACW-IY series is designed with a new strong birotor system with strong gears and robust birotor wings.

The semi-automatic string-up device simplifies the stringup process for the operator, hence improving efficiency by ensuring a fast and reliable string-up.

Smooth surfaces and the carefully considered layout of the components ensure that the ACW is a maintenance-friendly, easy-to-clean unit.

Cost advantages The ACW winder series designed for IDY offer cost competitive production by supplying enforced components for IDY products up to 6,000 den per end or up to 16,000 den per winder. The robust design leads to: - High reliability; - Low maintenance requirements; - Long lifetime; - High utilization rate.

Technical Data Process

Low Denier IDY PET Low Denier IDY PA HT / X-SLS PA & PET HT / X-SLS PA & PET HT / X-SLS PA & PET HT / X-SLS PA & PET HMLS PET HMLS PET

Winder Type

ACW4IT-1500/12 ACW6IT-1500/12 ACW4IY-900/3 ACW4IY-1200/4 ACW4IY-1200/6 ACW4IY-1600/8 ACW7IY-900/3 ACW7IY-1200/4

Speed range Denier range [m/min] per end [den]

Max denier on winder [den]

Chuck Diameter [mm]

Stroke

2500-4000 2500-6000 2500-4000 2500-4000 2500-4000 2500-4000 2500-7000 2500-6600

7200 7200 9000 12000 12000 16000 6000 8000

110 125 94 94 94 125 110 110

95 95 250 250 170 170 250 250

50- 600 50- 600 1500-4000 1000-6000 200-2000 200-2000 1000-2000 1000-2000

[mm]

Bobbin Volume [dmÂł] at 360 mm 10,2* 9,9* 23,2 23,2 15,7 14,7 22,4 22,4

*= Full Bobbin Diameter = 390mm IDY solutions – Oerlikon Barmag

35


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 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, 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. With the available modules: Job disposition, Job View and Job Reports, the POC System functionalities can be expanded to establish the perfect link between the Plant Operation Center (POC) and the ERP (Enterprise Resource Planning) systems of the textile industry. With this technology, the POC really goes MES and is upgraded to a fully-functional Manufacturing Execution System.

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IDY solutions – Oerlikon Barmag


The POC creates transparency – the “Job Reports” module The status of manufacturing jobs is graphically displayed per spinning machine and/or per spinning position at all times. 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 simplifies the workflow – the “Recipe Management” module Recipes define what will be produced. They include the complete list of all set-points or parameters that are important for the product. During production planning, recipes are distributed to the production units.

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.

IDY solutions – Oerlikon Barmag

37


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. Partnering for performance 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 – wherever you are. Local repair shops and on-site workshops at your production plant are characteristic of 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. 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 all times, 24 hours a day and throughout the year. The customer portal has a clearly arranged and uniform website covering all busi-

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IDY solutions – Oerlikon Barmag

ness units and their respective product lines. Our customers have online access to the latest documentation, tailored to their specific machines. The troubleshooting manual permits quicker and more efficient alleviation 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. The latest encryption technology guarantees the maximum data security at all times.


IDY solutions – Oerlikon Barmag

39


Oerlikon Barmag Zweigniederlassung der Oerlikon Textile GmbH & Co. KG Leverkuser StraรŸe 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 / 8/2011 Studio 45 / Kรถllen Druck & Verlag, Bonn 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  

Solutions for IDY production At your service The primary Oerlikon Barmag markets are Asia, and China and India in particular, as well as the...

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