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Solutions for FDY manufacturing


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

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FDY 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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FDY 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 Mixing and metering Spinning head series SP8 x Spin packs Quenching systems Godets ACW i-QOON

18 20 22 24 26 27 28 30 32 34

Plant Operation Center (POC)

36

SUN – Service UNlimited

38

FDY solutions – Oerlikon Barmag

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

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

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

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

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

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FDY solutions – Oerlikon Barmag

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


A selection of reference projects

Engineering is one of the three supporting columns of Oerlikon Barmag’s solutions philosophy. In combination with cutting-edge technology and a comprehensive global service offering, engineering meets customer demand for an overall solution from a single source.

Engineering & construction: - Basic engineering - Detail engineering - Supervision of erection, commissioning and start up - Project management - Site management

A choice of projects demonstrates our expertise in the challenging field of plant engineering.

Project: Solution for PET FDY with guarantees Location: Morocco Plant type: spun-dyed PET-FDY spinning and winding, 6 Pos. with 8 ends Start up: January 2008

Project: The project covers a complete polyester plant from polycondensation up to monitoring the textured yarn. The polycondensation has a capacity of 100.000 tons per year and produces currently 100 tons a day of FDY. The spinning section consists of 4 lines with 24 positions at 24-end. For winding the yarn producer relies on the i-QOON twin winder, which offers an operation speed of up to 5,500 m/minute. Location: Start up:

India March 2010

Scope of supply: - Polycondensation - Transferline from polycondensation to spinning - Extruder, spinning, take up

Scope of supply: - Plant operation center (POC) - Chips feeding, crystallizing, drying & distribution - Masterbatch-chips conveying, drying and metering - Extruder, spinning with continuous polymer filter, take up - Advanced side-stream injection (FLUMIX) - Spinning accessories such as spinneret preheating and cleaning system, spin-finish mixing and handling - Quench and take up air conditioning units Engineering & construction: - Basic engineering - Detail engineering - Process and product guarantees - Supervision of erection & start up Solution for coloured PET textile yarn with guarantees Location: Egypt Plant type: 12 Positions, 96-end PET FDY extrusion spinning plant, with yarn process guarantee Start up: November 2005 Project:

Scope of supply: - Chips conveying, storage - Chips crystallization, drying - MB chips drying, metering - Extruder, spinning, take up and accessories such as filter cleaning, godet exhaust system, laboratory,etc. - Quench and take up air conditioning units - Utility generation units like power generators, chillers, - Demineralised water and compressed air units Engineering & construction: - Basic engineering - Detail engineering - Supervision of erection & start up

FDY solutions – Oerlikon Barmag

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FDY spinning solutions Our customers’ productivity goals and market needs motivate our solutions. We provide the spinning machine that is just right for the specific market requirements for the production of high-quality FDY yarns made from PET, PA 6, PA 6.6, PP and others.

Low yarn deflection angles starting in spinning and further down at the take-up position result in a better yarn quality. Fewer yarn breaks mean a very efficient production, especially for multi-end spinning with more than 12 ends. Highly efficient FDY production with i-QOON Efficiency for yarn manufacturers is decisive in securing profit margins, particularly in the case of commodity yarns. Daily outputs of up to 600 tons require mature solutions – which ensure that a high performance does not come at the cost of quality. Correspondingly in demand are systems with multi-filament spinning and take-up plants, particularly in polyester FDY production. You will be perfectly prepared for this with our FDY systems, which produce up to 24 thread lines on a single spinning position. The core of these systems is the i-QOON twin winder, which offers an operation speed of up to 5,500 m/minute. Our machine layout ensures the lowest conversion cost per produced ton of yarn. The simple operation, low waste ratios and low energy costs underline the performance and efficiency of our FDY solutions. Conventional spinning with ACW Different materials require different technologies. To this end, polyamide can currently only be manufactured using conventional spinning systems. And the Oerlikon Barmag program offers proven components for this.

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FDY solutions – Oerlikon Barmag

For the FDY process, the ACW is available as a 6, 8, 10 or 12-end winder. In addition to high winding speeds, the top-quality packages offer yarn manufacturers decisive profit margins. High count yarn and microfilament yarn The production of high count (>100 filaments) yarn has special requirements for the spinning and take-up area. We support you with a wide range of spinning and quench systems applicable to different types of high count yarns. All components from spinning down to the winder are chosen to assure excellent yarn qualities. Control concept Generally, the drive concept of our FDY lines consists of individual inverters, which increase the system’s flexibility. The systematically applied “plug and work” design concept creates the ideal prerequisites for fast system installation and commissioning. The kinetic buffering system perfectly protects the system against short-term power outages. Yarn cuts, and hence unnecessary yarn waste, are avoided. The Profibus standard ensures that the FDY spinning system is universally expandable. The electrical design ensures electromagnetic compatibility. Energy efficient components Future-oriented technologies are energy-efficient. Our systems have been designed in accordance with this. e-save-certified components – such as our HF-technology godets – help you to maximize profits. The Central DC bus ensures an improved energy balance within the system and hence helps save on electricity costs.

POC (Plant Operation Center) Simple, user-friendly operation via the graphic interface of a PC display screen makes formulation management and data input of line and production parameters easier. A log function significantly simplifies service to the machine. Appropriate automation concepts - from process control to full bobbin and data tracking are available within the complete FDY product program.


FDY 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 FDY production systems. Today, they already cause up to 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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FDY solutions – Oerlikon Barmag


There are numerous possibilities for sustainably lowering the consumption of valuable resources. Firstly, there are energyoptimized components, for example Oerlikon Barmag’s SP8x spinning beam, which consumes more than 40% less energy than other more common designs. In a FDY spinning system with 144 positions, this generates an annual saving of approx. U$ 90,000. Reducing the consumption of process air is an important objective of the EvoQuench. Radial quenching consumes 60-80% less air than cross-flow quenching – and can be used for manufacturing microfilaments and commodity yarns of up to 1.5 dpf (FDY). Multi-filament spinning saves energy However, the utilization of efficient components is only one step on the path to creating smart production processes. Restricting the examination to the spinning system alone does not take important factors into account. Within this context, the multi-filament capability should definitely be considered an energy-saving factor. Spinning 24 end FDY using a spinning beam with DIO spin packs and a quenching unit serving 24 threadlines is therefore considerably more efficient than two 12-end spinning positions. A decisive associated factor that influences the overall energy consumption is the air-conditioning system. Drives, heating systems, components that come into contact with the melt as well as the filaments radiate heat. If this heat radiation is reduced by means of excellent insulation, the air-conditioning system can be small, hence itself using less energy. Oerlikon Barmag – with its focus on innovation and technological leadership – provides a variety of machines, components and solutions that stand out through their excellent resource efficiency and thus easily fulfill the requirements defined by the e-save label.

FDY solutions – Oerlikon Barmag

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Process solutions

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

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FDY solutions – Oerlikon Barmag


FDY solutions – Oerlikon Barmag

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Polyester 10 to 12 ends

Flexible with a wide working window: this is the motto of our 10- to 12-thread lines systems for manufacturing polyester FDY. Microfilament yarns, trilobal products, spun-dyed filaments, high titers and particularly high package weights – the systems fulfill all these demands. All process-influencing system components, such as the spin-finish system, the migration nozzle, godet surfaces and the tangling unit, are precisely geared to each other, hence guaranteeing the very best yarn quality. The machines are equipped with the proven ACW winder. Downstream processing companies favor ACW packages particularly because of their excellent take-off performance. Many of the units used come with the e-save certificate. This means that these components are characterized by particularly low energy consumption. The SP8x spinning head stands out here with its improved thermal insulation. The HF godet heater focuses the heating energy on the godet jacket as this is the only part that needs to be heated.

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Process Final titer Single filament titer Filament count Ends per position Mechanical speed Chuck length Extruder or direct spinning Spinning beam series Quenching systems Winder type series

30 - 600 den 0.5 - 4.0 dpf 12 - 288 10, 12 2500 - 6000 m/min 1380, 1500 SP8x SP82, EvoQuench ACW

Technical data are dependent on operation conditions. Not all values can be combined.


FDY solutions – Oerlikon Barmag

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Polyester 20 to 24 ends

Economical manufacturing of commodity yarns. This forms the basis of our 20- and 24-thread lines polyester FDY systems. Numerous details perfectly combined and tuned to each other ensure production success within a challenging market segment. Lost your thread? You won’t with us! An elaborate yarn guide guarantees record low string-up times. And the stable yarn path in our systems guarantees high full package yield. Using the i-QOON winder you can wind up 20 or 24 packages simultaneously. And you can also handle 24 yarn ends with the extensively automated string-up technology.

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FDY solutions – Oerlikon Barmag

Process Final titer Single filament titer Filament count Ends per position Mechanical speed Chuck length Extruder or direct spinning Spinning beam series Quenching system Winder type series

40 - 150 den 0,5 - 3.0 dpf 24 - 144 20, 24 2500 - 6000 m/min 2 x 1200 mm, 2 x 1380 mm SP8x SP82, EvoQuench i-QOON

Technical data are dependent on individual operation conditions. Not all values can be combined.


FDY solutions – Oerlikon Barmag

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Polyamide 6 and 6.6

Polyamide yarns and the fabrics manufactured using them stand out as a result of numerous excellent properties. Deep dyeing at low temperature, a soft and pleasant fabric handle and also elasticity (high elastic recovery) are just a few of these properties. Particularly the high elasticity places huge demands on the system configuration: using a fifth godet positioned upstream to the winder achieves a considerably better package build vis-Ă -vis conventional systems. This is especially beneficial when manufacturing microfilament yarns and exceptionally fine titers. Needless to say, the polyamide flat yarn systems also draw on units that have proven themselves in the polyester production process, such as HF6 godets and ACW winders. Therefore, the system offers a broad titer range, simple handling, reliable components and excellent yarn quality.

Process PA 6 Final titer Single filament titer Filament count Ends per position Mechanical speed Chuck length Extruder spinning Spinning beam series Quenching systems Winder type series Process PA 6.6 Final titer Single filament titer Filament count Ends per position Mechanical speed Chuck length Extruder spinning Spinning beam series Quenching systems Winder type series

10 - 210 den 1.0 - 4.4 dpf 3 - 96 8, 10, 12, 16 2500 - 6000 m/min 1200, 1380, 1500, 1600 SP8x SP82 ACW

10 - 100 den 1.0 - 4.2 dpf 3 - 96 8, 10 2500 - 6000 m/min 1200, 1500 mm SP8x, SP4x SP82 ACW

Technical data are dependent on individual operation conditions. Not all values can be combined.

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FDY 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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FDY 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. Oerlikon Barmag extruders are chracterised by a good barrel insulation resulting in energy savings and a low surface temperature on the barrel jacket. The two-step spur gear guarantees long service life and smooth running. The feed area for inert gas or vacuum is designed to prevent oxidation of the polymer, thus ensuring trouble free spinning. Specially matched screw and barrel materials result in good sliding properties and low wear.

Air-cooled extruder series These are the perfect choice for processing PETP, PA6, PA66, PP and other spinning polymers in all viscosity ranges for all manmade fiber requirements. An output ranging from 3 kg/hr to 1,500 kg/hr is possible. This extruder version includes a fine-graduated program with screw diameters from 30 to 250 mm, and screw lengths of 30 L/D or 24 L/D. Further, the specifically-cooled barrel sections expand the production window. The additional feature offered for this series is the control cabinet, which is integrated into the extruder frame. This version transforms our well-established model into a compact unit with significantly less wiring. All versions are available with or without a cooling system for the barrel. An injection system introducing master-batches or liquids into the polymer stream at various locations for customized fiber characteristics is also available.

Throughput capacity 24D PET PA6 PA6.6

max. max. max.

kg/h kg/h kg/h

30D PET PA6 PA6.6 20

max. max. max.

kg/h kg/h kg/h

FDY solutions – Oerlikon Barmag

4E

6E

7E

9E

10E

12E

15E

17E

70 40 40

130 80 70

200 125 120

300 200 180

400 270 240

520 350 315

820 550 -

1120 750 -

4E

6E

7E

9E

10E

12E

15E

17E

90 45 45

160 90 90

260 145 140

380 230 200

500 310 280

660 400 380

1000 630 -

1380 -


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Pumps in a spinning plant

Booster pumps Booster pumps build up the pressure which is required by the system – with a high degree of flexibility and reliability. Booster pumps in polymerization or polycondensation plants, also known as transfer pumps, receive the necessary supply pressure from the discharge pump. These are used to provide the necessary pressure for the downstream consumer units. These consumer units include spin 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: - 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.

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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 planetary concept is based on the proven planetary gear pump principle with a centrally driven sun gear and four planetary gears in each level. With four outlets per level this design is very space saving. 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, only one spin finish pump would suffice for a double spin finish system. This series is designed for use with all commercially available types of spin-finish, from high down to low oil concentration. PROFIN Feed accuracy, operating stability, and servics 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.


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Mixing and metering systems

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

Powered 3DD mixer One or more additive flows can be added to the main melt flow upstream to the mixer. The constant changing of the rotor/stator groove allocation creates a dynamic 3-dimensional flow that includes both a longitudinal, dispersive and distributive mixing result. Technical data powered 3DD mixer Type

Ø (mm)

throughput kg/h*

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

75 105 150 175 200 225

260 500 1000 1400 1800 2300

* textile PET

Additives and dyes for plastics are becoming an increasingly important part of the manufacturing process. The properties of the polymers can be extensively modified as a result of additives. The option of directly introducing these additives during the manufacturing process (e.g. fibers or films) provides a high degree of flexibility and increased efficiency. The dynamic, three-dimensional mixing principle has proven to be an excellent choice when feeding additives, dyes, stabilizers and other polymers. Pumps for liquid additives or compact combination of injection extruders with gear pumps are used for feeding. The systems can be integrated in various areas of the melt system. Feed options Additives can be fed into the polymer at various points. The appropriate point must be determined, taking flexibility and costs for each process individually into consideration.

Feed position

Extruder hopper

At 3DD mixer on the extruder

At powered 3DD mixer

form of additive flexibility costs

granulate 0 ++

melt; liquid additive 0 +

melt; liquid additive + 0

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FDY solutions – Oerlikon Barmag


Feed extruder with metering pumps These components are required whenever master batch melts need to be metered into the main melt flow under high pressure. Throughput volumes from 3 kg/h can be metered.

Inject AC - metering system for liquid additives This system was developed for feeding liquid dyes and additives into plastic granulate (unpressurized) or polymer melt (pressurized). One metering pump is used for unpressurized feeding.

3DD mixer as an extruder extension This mixing unit is attached to Oerlikon Barmag extruders as a screw and cylinder extension. The master batches to be added are either fed via the extruder hopper (granulate) or later into the mixing zone (melted up, liquid). The mixing zone can be separately heated or cooled.

When feeding under pressure, two metering pumps in series are used, whereby the first pump carries out the pressure build-up and the second the high-precision metering. The speeds of both pumps are set using an intelligent control system.

Powered 3DD mixer as a separate unit This unit is a hot melt extruder with a dynamic mixing function. Here, the pressure differential required for mixing is extensively compensated by the pressure build-up in the screw section. The speed can be selected in accordance with the mixing task. The melt temperature can be influenced by the air-cooled mixing cylinder. The mixer is designed for integration into melt distribution systems for larger throughput volumes (> 100 kg/h). Both melt and liquid mass flows can be fed in.

The system can be completed with pressurized tanks with electrical filling height monitoring and valves. Valve technology enables fast dye changes using a rinse mode.

Promix AC For customized feeding of additives or dyes (liquid) at the spinning position, this planetary gear pump offers an injection function. To this end, the dynamic mixer works synchronous to the pump speed. Pumps with 3, 4, 5, 6, 8, 10, 12 or 16 outlets are available. Promix VS To be able to tend to the mixing and metering functions separately in terms of process, a unit with 2 separate drives for mixing and metering was developed. The unit can be integrated into spinning positions or upstream into the melt distribution system.

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Spinning head series SP8x

First-class spinning heads make first-class yarns make first-class profits! The quality of the thread is determined during spinning. The manifold in an Oerlikon Barmag spinning line is specially optimized regarding melt residence time, pressure drop 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 almost maintenance-free.

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. This system also enables the production of microfilaments without loss of quality and productivity and excellent productivity for standard titers.

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

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

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

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

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Spin packs

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

The advanced spin pack is available as the proven self sealing version, however, for the production of polyamide 6.6 we supply a forced sealing version. Double-in-one When looking at throughput, FDY systems for small titers require a relatively high level of investment. The 24-fold Double-in-one (DIO) spinning plant concept has been able to considerably reduce the investment costs while maintaining yarn quality. The DIO concept, with two completely-independent spinnerets in one base, allows manufacturers to use approx. 30% less space vis-Ă -vis single packages while retaining the titer evenness. Microfilaments with 24 ends can be efficiently manufactured if the DIO technology is combined with the EvoQuench system.

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Quenching systems

The main task of the quenching system within the context of complex spinning processes is the even quenching of the liquid filaments at the exit of the spinneret. Oerlikon Barmag quenching systems supply a uniform, turbulence-free airflow for achieving excellent uster values. During the quenching process, each filament is supplied with the same amount of cooling air, hence ensuring defined crystallization and orientation of the polymer molecules basis for optimal uster, elongation and dyeability. For this reason, the quenching process has a decisive influence in achieving excellent yarn qualities in the synthetic filament manufacturing process. Moreover, all current processes are covered by this system e.g. PET, PA 6, PA 6.6, PP and others. Quenching systems: quality assurance also for microfiber yarns We provide different quenching systems especially designed for our customers’ needs: The standard cross-flow quench system is suited for standard yarns and microfiber yarns higher than 0.7 dpf (denier per filament). The cross-flow quench system with quench booster stabilizes the production of yarns in the 0.7 to 1 dpf range. For the production of PET high-count yarns and microfiber yarns, we recommend the EvoQuench system, which allows for either a 10 to 12 end machine with up to 288 filaments (and filament counts down to 0.5 dpf) or a 20 to 24 end machine with up to 144 filaments. The Windows-based GUIDE system controls the airflow. Various quench air profiles, depending on the process requirements, are available.

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FDY solutions – Oerlikon Barmag


Cross-flow quenching system – one unit for (almost) everything This quenching system is the number one choice for all commodity applications. Robust, easy to use, suitable for a broad range of titers and all standard polymers, the Oerlikon Barmag cross-flow quenching system feels at home in almost all FDY spinning processes. As a result of the specially constructed rectifier, which corresponds to all requirements in terms of even and laminar air, extremely high yarn qualities can be achieved. EvoQuench – something innovative from the technology leader In contrast to the cross-flow, the air here is symmetrically guided from the outside of the thread bundle to the inside. This ensures optimal cooling-air flow of the thread along the entire length of the yarn surface. The EvoQuench system

was developed for microfiber yarns with low filament count, but also covers a good range of commodity yarns. With more than 3500 installed positions the EvoQuench system is on its way to become a sales hit made by Oerlikon Barmag. e-save with EvoQuench In the quenching unit, it is the consumption of controlledprocessed compressed air that is the criterion that determines the resource consumption and hence the conversion costs. Depending on the titer and dpf, Oerlikon Barmag’s EvoQuench unit reduces the air requirements by between 70% and more than 80% compared to a cross-flow quenching unit. The air savings per spinning position add up to more than 20,000 m³ every year.

FDY 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. 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. High productivity and competitiveness is ensured thanks to the following basic requirements: - Robust design; - Achievable process speeds; - Low operating cost; - Reduced maintenance times; - The suitable godets for all MMF processes.

Godets for the FDY process For years, the HF godet series has been well-established in production facilities throughout the world and offers proven advantages. High-precision setting and control of heater temperatures with large godet working width, due to: - Inductive high-frequency heaters, based on the multi-zone principle, ensuring high efficiency and, therefore, minimum heat loss; - Individually controlled heating zones, each monitored by a temperature sensor. All HF godets have high godet shell wear-resistance. The shell and all other parts of our godets have a nickel surface, which is extremely corrosion-resistant, even in the case of aggressive media such as spin finishes and oligomers. The godet shell surface is available in ceramic or other coatings.

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.

The number of yarn ends per position have continuously increased from 8 to 12 to 24 ends. However, our godets achieve nearly the same yarn properties for all processes, regardless of the number of yarn ends.

Dependable quality at high output rates Stable operation, even at the 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.

Lower energy consumption Compared to other godet heating concepts, the HF principle has 20% less power consumption than, for example, 50Hz heat pipe systems. The HF godet family thus easily fulfills the requirements for the e-save label. The energy savings are, independent of the increasing number of yarn ends per position, more than 1 kWh 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.

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FDY solutions – Oerlikon Barmag

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.


Technical data Godets Speed Diameter Length Max. temperature Lubrication Draw force

[m/min] [mm] [mm] [°C] [N]

HFO250-535V60

HFG220-400V60

HFG220-480V35

HFG220-545V35

400 - 6000 250 535 110 / 160 Barolub 31

350 - 6000 220 400 200 Grease 35

350-3500 220 480 110 Grease 35

350 - 3500 220 545 110 Grease 35

FDY solutions – Oerlikon Barmag

31


ACW

The ACW – Advanced CRAFT Winder – represents the next generation of the successful CRAFT winder program. It incorporates many new features while retaining the essential characteristics and advantages of the preceding generation.

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. 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 sensorcontrolled yarn catcher guarantees 100% unifor-mity for the transfer and the end locator. As a result of the electrically driven bale rolls, the form of the packages can be influenced, hence enabling a qualitatively specified further processing. Efficient operating An extended parking time allows for 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 traverse motion unit. 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 simpli-

fies 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. Production optimization To optimize the production processes, the ACW has a unique first yarn break detection system for determining the precise position of the yarn break. This feature is unique because the signaling of yarn breaks in the millisecond range enables accurate error and process analysis. The measured data is transferred to the plant operation center (POC) for statistical evaluation. Hence, the POC reliably supports the continual optimization of the plant.

Technical data Winders for polyester processing Version chuck length / ends mm / [ ]

speed max. [m / min.]

denir range / yarn end den / final

tube inner Ø [mm]

package max. Ø [mm]

ends [x] stroke length [mm] volume [dm3]

ACW-5T 1380/12 ACW-6T 1500/10

3,500-5,500 3,500-6,000

50-300 200-600

110 125

440 440

12 x 91 / 12.7 10 x 120 / 16.7

Winders for polyamide processing Version chuck length / ends mm / [ ]

speed max. [m / min.]

denir range / yarn end den / final

tube inner Ø [mm]

package max. Ø [mm]

ends [x] stroke length [mm] volume [dm3]

ACWW-5T 1600/16 ACW-6T 1500/10 ACW-6T 1500/12

3,500-4,800 3,500-6,000 3,500-6,000

8-100 8-240 8-240

125 125 125

440 440 440

16 x 76 / 10.4 10 x 120 / 16.7 12 x 95 / 13.3

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FDY solutions – Oerlikon Barmag


FDY solutions – Oerlikon Barmag

33


i-QOON

The i-QOON concept combines principally two winders in a single unit, with a total of 4 chucks. The winders are equipped with1,200 mm and 1,380 mm long chucks, which achieve stroke lengths of 95 mm and 91 mm. The i-QOON winds up its packages with a maximum speed of up to 6,000 m/min.The specification of these winders is perfectly suited for FDY processes (high-speed). The birotor traverse systems known from the SW6, CW and ACW winder series, which have been sold more than 24,000 times, have been improved for the i-QOON winder. Double the solution The i-QOON has been designed for maximum output. Up to 24 packages can be wound simultaneously with the twin winder. Simply double the solution!

Technical data Version chuck length / ends mm / [ ]

speed max. [m / min.]

denir range / yarn end den / final

tube inner Ø [mm]

package max. Ø [mm]

ends [x] stroke length [mm] volume [dm3]

i-QOON-5B 1380/24 i-QOON-6B 1200/20

3,500-5,500 3,500-6,000

20-100 20-150

110 110

440 440

24 x 91 / 12.7 20 x 96 / 13.4

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FDY solutions – Oerlikon Barmag


FDY solutions – Oerlikon Barmag

35


Plant Operation Center 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.

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FDY solutions – Oerlikon Barmag

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.


POC Scheduled Reports The POC Scheduled Reports allows automatic generation and distribution of POC standard reports.

sent as PDF-files per e-mail to one or several recipients, or printed to up to three printers.

The user can freely configure the report period as well as the exact times of generation and distribution of the report. It applies to POC standard reports: - Production Report - Shift Report - Yarn Break Statistics

POC Trending The POC Trending shows the development of important process signals over a time axis. These may be analog or digital actual values. The composition of process signals for a diagram can be configured at will. It is possible to display up to 500 diagrams. Scaling over both axes – values and time – can also be selected at will.

The automatically generated reports are either stored as PDF-files in the database of the Pant Operation center, or

The process signals are archived for 3 months (option: 6 months).

Feature Overview Feature

Description

Availability

POC User Management

The POC User Management provides a powerful and flexible tool for the plantwide administration of the user accounts.

Desktop

POC Shift Management

The POC Shift Management provides a powerful and flexible tool for the administration of the plantwide shift calendar.

Desktop

POC Recipe Management

The POC Recipe Management provides a central plant wide management of recipes.

Desktop

POC Production Report

The POC Production Report provides information about the accumulated production results of a production plant.

Desktop Web Mobile

POC Shift Report

The POC Shift Report provides information about the shift related production results of a production plant.

Desktop Web Mobile

POC Yarn Break Report

The POC Yarn Break Report provides information about the total yarnbreak situation in a production plant.

Desktop Web

POC Plant Overview

The POC Plant Overview provides information about the machine status in a production plant.

Desktop Web Mobile

POC Alarm Management

The POC Alarm Management and Event Protocol provides a plantwide chronologic log of all machine and position related stopping codes and further production relevant events (i.e. shift changes).

Desktop Web

POC Sampling

With POC Sampling you get the opportunity to mark those packages to be lab-examined subsequently.

Desktop Web

POC Scheduled Operations

The POC Scheduled Operations provides a plant wide overview about scheduled activities at a spinning machine.

Desktop Web

POC Label Center

To be able to identify bobbins post doff you have to put labels into the paper tubes.

Desktop

POC Reports and Statistics

FDY 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. 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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FDY 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.


FDY solutions – Oerlikon Barmag

39


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 206 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_FDY.pdf  

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

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