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Solutions for IDY production - Oerlikon Barmag - Oerlikon Textile

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<strong>Solutions</strong> <strong>for</strong><br />

<strong>IDY</strong> <strong>production</strong>


As creative as the market<br />

<strong>Oerlikon</strong> <strong>Barmag</strong>, a division of<br />

<strong>Oerlikon</strong> <strong>Textile</strong> GmbH & Co. KG<br />

with sites in Remscheid, Chemnitz,<br />

Wuxi and Suzhou (both<br />

People’s Republic of China), was<br />

founded as <strong>Barmag</strong> AG in 1922.<br />

The company is the world market leader<br />

<strong>for</strong> spinning systems and equipment<br />

<strong>for</strong> manmade fibers, such as polyester,<br />

nylon and polypropylene, and texturing<br />

machines and – as a service provider –<br />

offers engineering solutions <strong>for</strong> the<br />

entire textile value added chain.<br />

High-tech from the market leader<br />

Its core competencies also include the<br />

<strong>production</strong> of the associated components<br />

<strong>for</strong> manufacturing manmade<br />

fibers, such as extruders, winders,<br />

pumps and godets. As a future oriented<br />

company <strong>Oerlikon</strong> <strong>Barmag</strong>’s research<br />

2 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

and development is driven by the idea<br />

of energy-efficiency and sustainable<br />

technologies. With the expansion of the<br />

product range to include poly-condensation<br />

systems and their key components,<br />

the company now caters to the<br />

entire process – from the monomer all<br />

the way through to the textured yarn.<br />

At your service<br />

The primary <strong>Oerlikon</strong> <strong>Barmag</strong> markets<br />

are Asia, and China and India in<br />

particular, as well as the Middle East<br />

and Europe. Correspondingly, the<br />

company – with its approximately<br />

1,600 employees – has a worldwide<br />

presence in 120 countries as part of<br />

the <strong>Oerlikon</strong> <strong>Textile</strong> network of <strong>production</strong>,<br />

sales and distribution and service<br />

organizations. At the <strong>Oerlikon</strong> <strong>Barmag</strong><br />

R&D Center – the largest of its kind in<br />

the world – within the company’s head-<br />

quarters in Remscheid, highly-qualified<br />

engineers and technicians develop<br />

innovative and technologically-leading<br />

products <strong>for</strong> tomorrow’s world.<br />

<strong>Oerlikon</strong> <strong>Barmag</strong> machines and components<br />

rely on a large number of<br />

registered trademarks and international<br />

patents.


Table of contents<br />

Plant engineering 4<br />

<strong>IDY</strong> spinning solutions 6<br />

e-save – energy saving and more 8<br />

Process solutions 10<br />

Key components 24<br />

Melt preparation 26<br />

Pumps in a spinning plant 27<br />

Spinning head series 28<br />

Spin packs 29<br />

Quenching systems 30<br />

Godets 32<br />

ACW 34<br />

Plant Operation Center (POC) 36<br />

SUN – Service UNlimited 38<br />

<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

3


Plant engineering<br />

Consulting, engineering, plant construction and high-tech machinery – the whole package from a single<br />

source. Many years of experience in textile machine construction and <strong>Oerlikon</strong> <strong>Textile</strong>’s strong global<br />

network <strong>for</strong>m a solid basis and the perfect prerequisites <strong>for</strong> <strong>Oerlikon</strong> <strong>Barmag</strong> as a solutions provider.<br />

A harmonized chain of poly-condensation, spinning and down-<br />

stream machines allows efficient <strong>production</strong> which results in<br />

an increase of added value <strong>for</strong> the customer. We ensure the<br />

harmonization of all machines and lines in an optimum manner,<br />

providing our customers with the respective know-how.<br />

In plant engineering and construction, the term plant design<br />

means turnkey construction. This means that – from the<br />

feasibility study all the way through to the implementation of<br />

projects – customers receive all services from a single source.<br />

<strong>Oerlikon</strong> <strong>Barmag</strong> plant engineering delivers the following<br />

services:<br />

- Feasibility study;<br />

- Consulting services;<br />

- Engineering services;<br />

- Plant layout;<br />

- Basic and detail engineering;<br />

- Procurement, expediting and inspection;<br />

- Process know-how and technology;<br />

4 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

- Guarantees <strong>for</strong> product and <strong>production</strong>;<br />

- Supervision of erection and start-up;<br />

- Operator training;<br />

- Site management.<br />

Examples of engineering services are:<br />

- Project management;<br />

- Plant layout and process engineering;<br />

- Mechanical engineering;<br />

- DCS, electrical and instrumentation engineering;<br />

- PCS engineering;<br />

- Piping engineering;<br />

- Energy and utilities engineering;<br />

- Data and technical documentation;<br />

- Operating instructions.<br />

Our plant engineering looks after the complete processes,<br />

from the poly-condensation to coated and dipped fabric and<br />

includes chip handling, auxiliary plants, utility plants, general<br />

electrics as well as the respective documentation.


A selection of reference projects<br />

Engineering is one of the three supporting columns<br />

of <strong>Oerlikon</strong> <strong>Barmag</strong>’s solutions philosophy. In conjunction<br />

with cutting-edge technology and a comprehensive<br />

global service offering, engineering<br />

meets customer demand <strong>for</strong> a total solution from a<br />

single source.<br />

A selection of projects demonstrates our expertise<br />

in the challenging field of plant engineering.<br />

Project: PET tire cord<br />

Location: Belarus<br />

Plant type: 3 positions, HMLS extrusion spinning plant,<br />

with yarn process guarantees<br />

Start-up: June 2008<br />

Scope of supply:<br />

- Chip conveying & storage<br />

- Chip drying unit<br />

- Extruder, spinning, take-up and accessories<br />

Project: PET industrial yarn<br />

Location: United Arab Emirates<br />

Plant type: 8 positions, PET industrial yarn extrusion<br />

spinning plant, with yarn process guarantees<br />

Start-up: 2009<br />

Scope of delivery:<br />

- SSPC<br />

- Chip conveying, storage<br />

- Chip crystallization and drying<br />

- Extruder, spinning and take-up<br />

- Quench air and take-up air conditioning system<br />

- Utility generation<br />

- Accessories such as mechanical workshop<br />

- Chemical and textile laboratory<br />

Project: PET tire cord and industrial yarn<br />

Location: Brazil<br />

Plant type: 4 x 4 positions, industrial yarn<br />

extrusion spinning plant, with yarn process<br />

guarantees<br />

Start-up: 2007<br />

Scope of delivery:<br />

- Chip conveying, storage<br />

- Extruder, spinning and take-up<br />

- Quench air and take-up air conditioning units<br />

- Utility generation<br />

- Accessories such as spinneret cleaning system, chemical<br />

and textile laboratory<br />

Project: PET industrial yarn<br />

Location: Spain<br />

Plant type: 2 + 2 positions, PET industrial yarn extrusion<br />

spinning plant, with yarn process guarantees<br />

Start-up: April 2010<br />

Extension: Start-up July 2011<br />

Scope of delivery:<br />

- Chip conveying, storage<br />

- Extruder, spinning and take-up<br />

- Quench air and take-up air conditioning units<br />

- Accessories<br />

Project: PET industrial yarn<br />

Location: Brazil<br />

Plant type: 3 x 4 Positions, PET industrial yarn extrusion<br />

spinning plant, with yarn process guarantees<br />

Start-up: 2012<br />

Scope of delivery:<br />

- Chip drying, conveying, storage<br />

- Extruder, spinning and take-up<br />

- Quench air and take-up air conditioning system<br />

- Utility generation<br />

- Chemical and textile laboratory<br />

<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

5


<strong>IDY</strong> spinning solutions<br />

6 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong>


Tires, safety belts, airbags, coated tarpaulins, conveyor belts –<br />

there are countless applications <strong>for</strong> industrial yarns manufactured on<br />

<strong>Oerlikon</strong> <strong>Barmag</strong> machines.<br />

Correspondingly specific are the demands made on the used yarns.<br />

Decades of research and a constant dialog with customers ensure<br />

that our systems produce the perfect yarn <strong>for</strong> each and every application.<br />

Flexible<br />

With its highly-developed components,<br />

know-how and proven technology, our<br />

industrial yarn machines manufacture<br />

extremely fine yarns all the way through<br />

to top-quality coarse yarns and – depending<br />

on the yarn fineness – up to<br />

24 ends per winding position.<br />

Our industrial yarn systems are available<br />

in several machine configurations:<br />

- 4 heated godet duos <strong>for</strong> hightenacity<br />

and low-shrinkage yarns at<br />

conventional speeds<br />

- 5 heated godet duos <strong>for</strong> high-tenacity<br />

and super-low-shrinkage yarns<br />

at conventional speeds<br />

- 4 heated godet duos <strong>for</strong> PET heavy<br />

denier yarns of up to 18,000 den per<br />

position at conventional speeds<br />

- 5 heated godet duo HMLS configuration<br />

<strong>for</strong> polyester tire cord yarn at<br />

high speed, also suitable <strong>for</strong> HT/LS<br />

yarn<br />

- 4 heated duo low denier <strong>IDY</strong> lines <strong>for</strong><br />

24 ends<br />

- 2 heated duo low denier <strong>IDY</strong> lines <strong>for</strong><br />

medium tenacity 24 ends<br />

- 5 heated godet duo safety yarn<br />

concept <strong>for</strong> PET seat belt and PET<br />

air bag yarn.<br />

All listed PET concepts can also be<br />

operated with direct spinning processes.<br />

Here, <strong>Oerlikon</strong> <strong>Barmag</strong> can supply<br />

the link to the melt finisher. Reference<br />

machines are already in operation.<br />

Efficient<br />

Depending on the process, titer and<br />

speed, yarn producers manufacture<br />

multiple threads per winding position.<br />

This is made quite simple by using<br />

<strong>Oerlikon</strong> <strong>Barmag</strong>’s industrial yarn systems:<br />

our flexible spinning plants are<br />

able to draw and wind four, six, eight,<br />

twelve, 16 or 24 threads simultaneously.<br />

Under control<br />

All process data – from the spinning<br />

through to the winder – are displayed<br />

via GUIDE, the Windows-based user<br />

interface. The GUIDE system permits<br />

total process control: product data<br />

management, <strong>production</strong> statistics,<br />

reporting – all this is just a fraction<br />

of what GUIDE provides to ensure<br />

continual optimization of the <strong>production</strong><br />

process.<br />

In the event of more than one <strong>production</strong><br />

line, we recommend using the<br />

Plant Operation Center (POC), which<br />

has an interface to all <strong>production</strong> lines.<br />

Air conditioning and other systems<br />

(down-stream), <strong>for</strong> example can also<br />

be integrated.<br />

<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

7


e-save – energy saving and more<br />

Think e-save and reduce your <strong>production</strong> costs! This<br />

is the motto under which <strong>Oerlikon</strong> <strong>Barmag</strong> started<br />

promoting energy-conscious machines and components<br />

in 2005. The combination of high-per<strong>for</strong>mance<br />

machines and systems, high flexibility and<br />

low conversion costs enables manufacturers to be<br />

successful market players.<br />

The focus of e-save is on the reduction of the conversion<br />

costs. In 2005, <strong>Oerlikon</strong> <strong>Barmag</strong> developed and launched<br />

the e-save label, which is awarded to those components<br />

whose energy consumption has been significantly reduced<br />

compared to standard components available on the market.<br />

Demands and inquiries from our customers have encouraged<br />

us to systematically further research and develop the<br />

approaches we have already taken. Like a stone thrown into<br />

a lake, e-save is creating ever more positive repercussions.<br />

In addition to energy-efficient components, <strong>Oerlikon</strong> <strong>Barmag</strong><br />

offers resource-minimizing solutions in many areas.<br />

Energy and environmental costs are also a not inconsiderable<br />

factor in <strong>IDY</strong> <strong>production</strong> systems. Today, they are<br />

already responsible <strong>for</strong> up to a half of the conversion costs of<br />

a spinning plant. All savings in this area benefit the local environment,<br />

while energy and resource efficiency are becoming<br />

ever more important location factors on a global level.<br />

8 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong>


There are numerous possibilities <strong>for</strong> sustainably lowering the<br />

consumption of valuable resources. Firstly, there are energyoptimized<br />

components, <strong>for</strong> example <strong>Oerlikon</strong> <strong>Barmag</strong>’s SP8x<br />

spinning beam, which consumes more than 40% less energy<br />

than other more common designs.<br />

Reducing the consumption of controlled-processed air is<br />

an important objective of a radial quenching system. Such<br />

a system consumes 60-80% less air than cross-flow<br />

quenching – it is available <strong>for</strong> the <strong>production</strong> of HMLS yarns<br />

with a high number of filaments.<br />

The influence of godets on the energy efficiency of a spinning<br />

system is also remarkable. The main effect of the HF<br />

godet technology is that the energy is only fed to the shell of<br />

the godet itself, the only part of the godet that actually needs<br />

to be heated. With the standard 50-Hz heating technology,<br />

this skin effect is negligible. For this reason, the 50-Hz heater<br />

needs at least 20% more energy which results from the<br />

power loss caused by heat distribution in the heater tube,<br />

the shaft and the front of the shell.<br />

Another advantage of the HF technology is the fast heat-up<br />

caused by the direct energy transfer, meaning that <strong>Barmag</strong><br />

godets react extremely fast to changes.<br />

Multi-end filament spinning saves energy<br />

However, the utilization of efficient components is only one<br />

step on the path to creating smart <strong>production</strong> processes.<br />

Restricting the examination to the spinning system alone<br />

does not take important factors into account. Within this<br />

context, the multi-end filament capability should definitely<br />

be considered as an energy-saving factor. Spinning 16- or<br />

24-end <strong>IDY</strong> using one spinning beam with especially de-<br />

signed spin packs, one quenching unit and one draw panel<br />

on two winders is there<strong>for</strong>e considerably more efficient than<br />

two 8- or 12-end spinning positions.<br />

A decisive associated factor influencing the overall energy<br />

consumption is the air-conditioning system. Drives, heating<br />

systems, components that come into contact with the<br />

melt and the filaments radiate heat. If this heat radiation is<br />

reduced by means of excellent insulation, the air-conditioning<br />

system can be small, hence itself using less energy. Furthermore,<br />

water-cooled godets and electrics generate a further<br />

reduction of the heat load within the take-up area.<br />

<strong>Oerlikon</strong> <strong>Barmag</strong> – with its focus on innovation and<br />

technological leadership – provides a variety of machines,<br />

components and solutions that stand out through their<br />

excellent resource efficiency and thus easily fulfill the<br />

requirements defined by the e-save label.<br />

Saving potential by multi-end technology<br />

One position with 16-ends spinning compared to two<br />

positions with each 8-ends spinning<br />

<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

9


Process solutions<br />

10 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

Our customers benefi t from the comprehensive optimization of<br />

individual processes along the textile value chain. Your big advantage<br />

is the fact that <strong>Oerlikon</strong> <strong>Textile</strong> serves the world’s largest<br />

range of applications in the textile machinery industry. Quality<br />

plays a huge role particularly in the industrial yarns sector. These<br />

materials are used in all applications where safety is paramount.<br />

Tires, safety belts, airbags, climbing harnesses – this is where<br />

quality is essential <strong>for</strong> survival. There<strong>for</strong>e, the right partner who<br />

has mastered the various processes perfectly is decisive.<br />

Technology and support go hand-in-hand<br />

Innovative machines and systems are just part of the story. Our<br />

solutions turn machines into teams. They integrate <strong>production</strong><br />

processes and harmonize every item of equipment perfectly with<br />

the next. Customers profi t from <strong>Oerlikon</strong> <strong>Barmag</strong>’s comprehensive<br />

process know-how along the poly-condensation, spinning and<br />

downstream steps in the textile value chain.<br />

<strong>Oerlikon</strong> <strong>Barmag</strong>’s solutions take a big weight off customers’<br />

minds. Our one-stop-shop covers everything from fi nance through<br />

to turn-key plants. Top machinery, comprehensive process skills,<br />

professional advice and service are all in the package.


<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

11


Polyester <strong>IDY</strong> HT/LS (High-Tenacity / Low-Shrinkage)<br />

concept<br />

High-tenacity yarns are produced <strong>for</strong> applications in conveyor<br />

belts and other heavy fabrics. Another application sector with<br />

huge growing potential is Geotextiles. The high-tenacity, highmodulus<br />

and low-creep properties typically required <strong>for</strong> this<br />

application to keep soil and rocks in place can be perfectly<br />

achieved with our <strong>IDY</strong> high-tenacity yarn lines.<br />

Low-shrinkage is a particularly important feature in the<br />

processing of tarpaulins. The Low-Shrinkage (LS) yarns manufactured<br />

using this system have a shrinkage of only 4%, but<br />

nevertheless always remain even.<br />

Technical data<br />

Process PET HT / LS<br />

ends 4/8 6/12 8/16<br />

denier range<br />

(up to)<br />

8 X 1500<br />

4 X 3000<br />

2 X 6000<br />

12 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

12 X 1500<br />

6 X 2000<br />

High efficiency is the key feature of our concepts offering a<br />

product range of up to 18,000 den per position. High output<br />

per position is easily achievable with this system configuration.<br />

A huge advantage in terms of conversion costs.<br />

Furthermore, our systems are incredibly flexible: from<br />

6-end or 8-ends to 12-end or 16-ends – with just a few<br />

adjustments.<br />

The HT/LS machine concept can also be equipped with a<br />

system <strong>for</strong> manufacturing adhesive-activated yarns.<br />

16 X 1000<br />

8 X 2000<br />

4 X 4000<br />

Winder Type ACW4IY-1200/4 ACW4IY-1200/6 ACW4IY-1600/8<br />

ACW4IY-1200/4


<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

13


Polyester <strong>IDY</strong> X-SLS concept<br />

(X-tra Super-Low-Shrinkage)<br />

For applications <strong>for</strong> which even shrinkage of approximately<br />

4% is too high, fabric manufacturers require X-SLS Extra<br />

Super-Low-Shrinkage yarns. A challenge <strong>for</strong> all yarn manufacturers<br />

– but there is no reason to be nervous with <strong>Oerlikon</strong><br />

<strong>Barmag</strong> at your side. The shrinkage of X-SLS yarns produced<br />

on our systems can be lower than 1.5%.<br />

However, those planning to manufacture X-SLS yarns need<br />

not dispense with the high tenacity properties. Our system<br />

configurations permit the flexibility to produce either Super-<br />

Low Shrinkage (SLS) yarns with less than 2.5% shrinkage,<br />

X-SLS yarn with less than 1.5% or high-tenacity (HT) yarn<br />

Technical data<br />

Process PET X-SLS<br />

ends 4/8 6/12 8/16<br />

denier range<br />

(up to)<br />

8 X 1500<br />

4 X 3000<br />

14 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

12 X 1000<br />

6 X 2000<br />

16 X 1000<br />

8 X 2000<br />

Winder Type ACW4IY-1200/4 ACW4IY-1200/6 ACW4IY-1600/8<br />

with one machine layout. Furthermore, our systems are<br />

incredibly flexible: from 6 ends or 8 ends to 12 ends or<br />

16 ends – with just a few adjustments. And a total denier<br />

range up to 16,000 den offers an outstanding productivity<br />

per position.<br />

The perfect yarn uni<strong>for</strong>mity maximizes the fabric uni<strong>for</strong>mity<br />

after coating. These kinds of X-SLS yarns can even replace<br />

yarns previously manufactured in a two-step process.


<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

15


Polyester <strong>IDY</strong> HMLS<br />

(High-Modulus Low-Shrinkage)<br />

HMLS yarns are the product that not only car tires but also<br />

V belts, conveyor belts, marine ropes and hoses are made<br />

of. The benefit of this yarn – manufactured on <strong>Oerlikon</strong><br />

<strong>Barmag</strong> lines – is the high dimensional and thermal stability<br />

combined with a high tenacity and high modulus.<br />

This finally leads to a reduced amount of yarn required <strong>for</strong><br />

the same final product properties.<br />

For tire cord – as one of the main applications <strong>for</strong> PET HMLS<br />

yarns – the carcass determines the load-carrying capacity,<br />

the com<strong>for</strong>t of the tire and the dynamic behavior.<br />

Technical data<br />

Process PET HMLS<br />

ends 4/2<br />

denier range<br />

(up to)<br />

4 X 1500<br />

2 X 3000<br />

Winder Type ACW7IY-1200/4<br />

16 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

The process range of the <strong>Oerlikon</strong> <strong>Barmag</strong> line allows a wellbalanced<br />

strength-to-elasticity ratio under all circumstances.<br />

The <strong>Barmag</strong> HMLS concept has been engineered to produce<br />

a high per<strong>for</strong>mance yarn <strong>for</strong> various technical applications<br />

but also be flexibly convertible to run HT/LS yarns,<br />

allowing yarn manufacturers to quickly adapt their processes<br />

to changing market demands and requirements.


<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

17


Polyester safety yarn<br />

(seat belt and polyester airbag)<br />

Polyester filaments are offered at approx. 40-50% of the<br />

price of comparable polyamide filaments and are there<strong>for</strong>e<br />

becoming increasingly interesting as the material <strong>for</strong> airbag<br />

yarns. With the first commercial application in curtain<br />

airbags, this transition has just begun and is now expanding<br />

fast within Europe and the US markets.<br />

The <strong>Oerlikon</strong> <strong>Barmag</strong> safety yarn concept is also well<br />

prepared <strong>for</strong> this development. The special 8-end take-up<br />

design was engineered <strong>for</strong> the <strong>production</strong> of high dpf seat<br />

belt yarn with high-tenacity and non-break filaments, but also<br />

Technical data<br />

Process PET Safety Yarn<br />

ends 8/4<br />

denier range<br />

(up to)<br />

8 X 500<br />

8 X 1500<br />

4 X 2000<br />

Winder Type ACW4IY-1600/8<br />

ACW4IY-1200/4<br />

18 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

reveals its full potential <strong>for</strong> the high-quality demands in lower<br />

deniers that are used in the <strong>production</strong> of airbag yarns, <strong>for</strong><br />

example.<br />

The Single Filament Layer (SFL) – patent pending – technology<br />

ensures an extremely gentle yarn path and a very<br />

uni<strong>for</strong>m heating of the filaments using the SFL concept. This<br />

is the key factor <strong>for</strong> uni<strong>for</strong>m dye take-up.


<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

19


Polyester Low Denier <strong>IDY</strong> (LDI) Yarn<br />

<strong>Oerlikon</strong> <strong>Barmag</strong>’s systems <strong>for</strong> low denier industrial yarn<br />

cover the full range of high-quality, low-denier filaments,<br />

enabling customers to cover a wide variety of luggage,<br />

sewing and embroidery applications.<br />

The layout with 24 ends per position is the perfect solution<br />

<strong>for</strong> optimizing quality, per<strong>for</strong>mance and <strong>production</strong> costs.<br />

Technical data<br />

Process PET LDI<br />

ends 24<br />

denier range<br />

(up to)<br />

24 X 250<br />

24 X 500<br />

Winder Type ACW4IY-1500/12<br />

20 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong>


<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

21


Polyamide yarn concepts<br />

And we can also equip you <strong>for</strong> the gravel track: tire cord<br />

made from polyamide yarns is – due to its better ductility –<br />

more suitable <strong>for</strong> this application. We have the optimum<br />

configuration <strong>for</strong> your specific demands.<br />

Furthermore, our polyamide 6 and 6.6 processes also<br />

offer an extremely broad range of applications. Airbags,<br />

conveyor belts, sewing yarns, special safety clothing, sail<br />

cloth as well as fishing nets – just a small selection of the<br />

possibilities.<br />

On the other side, low-denier polyamide 6 and 6.6 yarns<br />

are particularly suitable <strong>for</strong> sports applications: as the base<br />

material <strong>for</strong> parachute silk, climbing harnesses and ropes –<br />

specifically those used in mountaineering – these yarns are<br />

often vital to life.<br />

On request, we can also adapt the layout <strong>for</strong> the <strong>production</strong><br />

of Super-Low-Shrinkage (SLS) yarns.<br />

Technical data<br />

Process PA<br />

ends 6/3 8/4<br />

denier range<br />

(up to)<br />

6 X 420<br />

6 X 700<br />

Winder Type ACW4IY-1200/6<br />

ACW4IY-900/3<br />

22 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

8 X 420<br />

8 X 700<br />

8 X 1260<br />

4 X 1680<br />

ACW4IY-1600/8<br />

ACW4IY-1200/4


© VAUDE,<br />

M. Attenberger<br />

<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

23


Key components<br />

24 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

First-class solutions comprise first-class machine systems manufactured<br />

using first class components. This commitment determines the<br />

quality of our components.<br />

<strong>Oerlikon</strong> <strong>Barmag</strong>’s product range comprises extruders all the way<br />

through to the winding systems <strong>for</strong> all components within a spinning<br />

plant. As a systems constructor, we know the importance of the<br />

individual process steps and each partial component.<br />

For this reason, all <strong>Oerlikon</strong> <strong>Barmag</strong> components have their own<br />

success story: we have been designing and constructing extruders<br />

since 1958, the company has nearly 90 years of experience in building<br />

pumps and has supplied in excess of 100,000 winders<br />

throughout the world since 1972.<br />

We are not content with merely tried-and-tested design – our mission<br />

statement is the continual further development of all components to<br />

achieve even greater efficiency and even better technical solutions<br />

<strong>for</strong> our customers.


<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

25


Melt preparation<br />

Extrusion equipment<br />

<strong>Oerlikon</strong> <strong>Barmag</strong> spinning extruders excel at gentle and homogeneous<br />

melt <strong>production</strong> and are noted <strong>for</strong> cost effectiveness,<br />

reliability, and long service life.<br />

The utilization of top-quality, low wear materials – in particular<br />

<strong>for</strong> the extruder cylinders and the extruder screw – ensure<br />

long-term, error-free operation. The screw geometries with<br />

special homogenizing components have been engineered<br />

to ensure short dwell times in order to keep the thermal and<br />

mechanical loads of the melt to a minimum – the basis <strong>for</strong><br />

excellent melt and hence first-class yarn quality.<br />

<strong>Oerlikon</strong> <strong>Barmag</strong> extruders fulfill the e-save energy saving<br />

requirements. The e-save label is awarded to systems and<br />

components that have energy consumptions significantly<br />

lower than standard equivalent systems and components<br />

available on the market.<br />

<strong>Oerlikon</strong> <strong>Barmag</strong> extruders are characterized by their excellent<br />

barrel insulation resulting in energy savings and a low<br />

surface temperature on the barrel jacket. The two-step spur<br />

gear guarantees long service life and smooth running. The<br />

feed area <strong>for</strong> inert gas or vacuum is designed to prevent<br />

oxidation of the polymer, thus ensuring trouble-free spinning.<br />

Specially matched screw and barrel materials result in good<br />

sliding properties and low wear.<br />

26 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

Air-cooled extruder series<br />

These are the perfect choice <strong>for</strong> processing PETP, PA6,<br />

PA66, PP and other spinning polymers in all viscosity ranges<br />

<strong>for</strong> all manmade fiber requirements.<br />

An optional feature offered is the control cabinet, which is<br />

integrated into the extruder frame. This version trans<strong>for</strong>ms<br />

our well-established model into a compact unit with significantly<br />

less wiring.<br />

All versions are available with or without a cooling system <strong>for</strong><br />

the barrel. An injection system introducing master-batches<br />

or liquids into the polymer stream at various locations <strong>for</strong><br />

customized fiber characteristics is also available.<br />

The extruder series ranges from 90-mm to 175-mm screw<br />

diameter and a throughput range from 40 kg/h to 720 kg/h.<br />

Direct spinning<br />

Cost competition in the <strong>IDY</strong> sector is also increasing. There<strong>for</strong>e,<br />

especially <strong>for</strong> high capacity installations/plants, the<br />

direct spinning technology is becoming more and more<br />

attractive. Some of the latest <strong>Oerlikon</strong> <strong>Barmag</strong> <strong>IDY</strong> lines are<br />

already operating successfully in a direct spinning process of<br />

this kind. For this technology, <strong>Oerlikon</strong> <strong>Barmag</strong> can engineer,<br />

design and provide the complete system <strong>for</strong> high IV melt<br />

distribution.


Pumps in a spinning plant<br />

Booster pumps<br />

Booster pumps build up the pressure required by the system<br />

– with a high degree of flexibility and reliability. Booster<br />

pumps in polymerization or poly-condensation plants, also<br />

known as transfer pumps, receive the necessary supply<br />

pressure from the discharge pump. These are used to provide<br />

the necessary pressure <strong>for</strong> the downstream consumer<br />

units. These consumer units include spinning pumps, flat<br />

nozzles, per<strong>for</strong>ated plates <strong>for</strong> granulation, etc. Frequently, the<br />

conditions within the system can also change, <strong>for</strong> example,<br />

through standstill of the downstream units. These demand<br />

flexibility; depending on the application even negative differential<br />

pressures can occur. <strong>Oerlikon</strong> <strong>Barmag</strong> booster pumps<br />

solve these tasks thanks to the universally applicable design<br />

of the bearing lubrication system.<br />

Planetary melt spinning pumps<br />

The spinning pump is one of the key components of a<br />

spinning system. Even when used over many years of<br />

<strong>production</strong>, all <strong>Oerlikon</strong> <strong>Barmag</strong> spinning pumps guarantee<br />

consistent yarn quality, the most important factor in successful<br />

yarn <strong>production</strong>.<br />

The special advantages of <strong>Oerlikon</strong> <strong>Barmag</strong>’s planetary gear<br />

spinning pumps include:<br />

- Optimum melt flow due to rheologically-advantageous<br />

melt channels;<br />

- Melt channels with optimized surfaces, ensuring superior<br />

flow conditions;<br />

- High-precision manufacturing methods, allowing <strong>for</strong> excellent<br />

running per<strong>for</strong>mance and stable melt exchange;<br />

- Specially-designed relief grooves in the melt outlet area of<br />

the gears, <strong>for</strong> minimized compression <strong>for</strong>ces and operation<br />

with few fluctuations in the flow.<br />

Together, these advantages translate into the uni<strong>for</strong>mity of<br />

the melt streams. Rectangular melt spinning pumps are<br />

available on request.<br />

Planetary spin-finish pumps<br />

The more even the application of the spin-finish liquid to the<br />

yarn, the better the yarn quality. A trailblazing design now<br />

sets considerably higher standards in terms of feeding<br />

accuracy, reliability and durability.<br />

The <strong>Oerlikon</strong> <strong>Barmag</strong> spin-finish pump concept is based on<br />

the old proven planetary gear pump principle with a centrally-driven<br />

sun gear and four planetary gears.<br />

The balanced <strong>for</strong>ce ratio within the pump and the constructively-influenced<br />

low bearing load guarantee low frictional<br />

wear.<br />

PROFIN<br />

Feed accuracy, operating stability, and service life of the<br />

equipment are the fundamental properties of our spin-finish<br />

pumps. As far as the PROFIN series is concerned, excellent<br />

feeding accuracy, optimum internal flow conditions and the<br />

self-venting effect – which prevents the agglomeration of<br />

air-bubbles – are the preconditions <strong>for</strong> precise, uni<strong>for</strong>m and<br />

high-quality oil-application.<br />

Mixing and metering in polymer processing<br />

Extremely-high metering accuracy and mixing per<strong>for</strong>mance<br />

ensure that your products are top quality. There is a series of<br />

systems available <strong>for</strong> the various feeding and mixing tasks,<br />

optimally designed to fulfill the requirements of flexible <strong>production</strong>.<br />

Color and additive injection is primarily used with textile<br />

filaments. Nevertheless, injection systems are available on<br />

request <strong>for</strong> producers interested in mixing and metering.<br />

<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

27


Spinning head series<br />

The quality of the thread is determined during spinning. The spinning components used provide your yarn<br />

with its ultimate qualities. There<strong>for</strong>e, they are particularly close to the hearts of our engineers.<br />

The manifold in an <strong>Oerlikon</strong> <strong>Barmag</strong> spinning line is speciallyoptimized<br />

in terms of melt residence time, drop in viscosity<br />

and shear rate. It is characterized by:<br />

- Flow-favorable melt distribution <strong>for</strong> excellent yarn uni<strong>for</strong>mity<br />

along the spinning line;<br />

- High surface quality of the pipes ensures favorable melt<br />

flow behavior <strong>for</strong> superior quality – from the very first day<br />

of <strong>production</strong>;<br />

- Absolute dead spot-free design is a precondition <strong>for</strong> low<br />

break levels and high yields;<br />

- The overall distribution system is virtually maintenancefree.<br />

<strong>Oerlikon</strong> <strong>Barmag</strong>’s spinning head series covers the processes<br />

<strong>for</strong> textile and industrial yarns as well as home textiles. For all<br />

applications, the spinning head vapor heating ensures excellent<br />

temperature uni<strong>for</strong>mity.<br />

28 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

e-save with SP8x<br />

The <strong>Oerlikon</strong> <strong>Barmag</strong> SP8x spinning head concept unites<br />

the advantages of high-end melt quality. The design of the<br />

spinning head has considerably reduced the heat-radiating<br />

surface and simultaneously significantly improved the insulation.<br />

This has resulted in a more than 40% reduction in the<br />

heat-radiation in comparison to the SP4x system.<br />

The SP8x spinning head ensures economic spinning processes<br />

with high product quality through its very even melt<br />

guidance system with optimized residence time. Furthermore,<br />

the shroud – which can be specifically adapted to the<br />

respective product on request – ensures an extremely high<br />

level of flexibility.<br />

Needless to say, the well-known self-sealing <strong>Oerlikon</strong> <strong>Barmag</strong><br />

spin packs can also be used <strong>for</strong> this system. The rheologically-optimized<br />

melt distribution and uni<strong>for</strong>m heating ensure<br />

that the excellent melt quality in the spinning head is also<br />

continued within the spin pack.


Spin packs<br />

All polymers place different demands on spin packs.<br />

The broad <strong>Oerlikon</strong> <strong>Barmag</strong> portfolio contains the<br />

suitable type <strong>for</strong> each and every raw material, optimized<br />

in terms of the rheological features of the<br />

melt-liquid polymers.<br />

Our range of spin packs caters perfectly to the product<br />

diversity of industrial yarns. Quick and easy retooling makes<br />

them compatible amongst each other. The filter media are<br />

predominantly 3LA or screen filter and metal powders.<br />

<strong>Oerlikon</strong> <strong>Barmag</strong> spin packs are available with diameters of<br />

104, 120, 135, 145, 165, 172 or 260 mm.<br />

3LA filters<br />

The metal filter fabric, commonly known as 3LA filter, which<br />

has meanwhile established itself on a global scale, is one of<br />

the most important <strong>IDY</strong> spin pack innovations. Its excellent<br />

properties<br />

- Outstanding evenness of polymer flow without dead<br />

spots;<br />

- Up to 5 times larger filter area compared to flat filter<br />

screens;<br />

- Reusable filter candles;<br />

- Longer life time;<br />

- Almost constant pack pressure over operation time;<br />

- Easy handling, ensuring constant process behavior and<br />

avoiding improper assembly;<br />

- Identical filtration conditions from position to position;<br />

- Reduced operating costs and yarn breaks;<br />

- Exchangeability with standard packs;<br />

clearly underline the superiority of the 3LA spin pack.<br />

For this reason, the 3LA spin pack is also standard in polyester<br />

and polyamide 6 spinning systems in <strong>Oerlikon</strong> <strong>Barmag</strong><br />

plants.<br />

Filter sands<br />

An alternative is, of course, the well-established filter methods<br />

using sand-like aggregates. Catering to the special<br />

features of PA6.6 when subjected to heat requires the use<br />

of quartz sands, metal powders or ceramic powders.<br />

Needless to say, these filter media with the <strong>Oerlikon</strong> <strong>Barmag</strong><br />

spin packs are also suitable <strong>for</strong> other materials such as<br />

polyester, polyamide 6 and polypropylene, to name but a<br />

few.<br />

Multi end spin packs<br />

The multi-end spin packs with two yarn ends out of one<br />

body are available <strong>for</strong> low-denier <strong>IDY</strong> lines basing on the<br />

well-established DIO pack principle or <strong>for</strong> the higher-denier<br />

<strong>IDY</strong> lines in our new 6LA design.<br />

The basic design principle <strong>for</strong> both concepts is:<br />

- Two spin packs in one body;<br />

- One pump outlet per end;<br />

- Two separated melt streams;<br />

- No hydraulic split -> Low den CV.<br />

This all result in lower space requirements compared to<br />

single-end spin-packs with a similar per<strong>for</strong>mance. This<br />

technology is the basis of our multi-end <strong>IDY</strong> processes with<br />

12, 16 or 24-end take-up.<br />

The new 6LA principle is based on the well-proven <strong>Oerlikon</strong><br />

<strong>Barmag</strong> 3LA filtration and now offers the same advantages<br />

such as outstanding evenness, high filtration area, long lifetime,<br />

good filter efficiency and reusable filters in a multi-end<br />

spin pack.<br />

<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

29


Quenching systems<br />

The main task of the quenching system within the context of complex spinning processes is the even<br />

quenching of the liquid filaments at the exit of the spinneret. Our quenching systems supply a uni<strong>for</strong>m,<br />

turbulence-free airflow <strong>for</strong> achieving excellent yarn uni<strong>for</strong>mity.<br />

During the quenching process, each filament bundle is supplied with the same amount of cooling air,<br />

hence ensuring defined crystallization and orientation of the molecular polymer structure as the basis<br />

<strong>for</strong> the optimal physical properties, elongation and dyeability. For this reason, the quenching process has<br />

a decisive influence in achieving excellent yarn qualities in the synthetic filament manufacturing process.<br />

Moreover, all current processes are covered by this system, e.g. PET, PA 6, PA6.6 and others.<br />

30 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong>


Crossflow quenching system<br />

The crossflow quenching system excels in terms of its<br />

extremely uni<strong>for</strong>m flow profile <strong>for</strong> even filament quality and<br />

thus highest evenness and per<strong>for</strong>mance. User-friendliness,<br />

in addition to the quality, is a further important criterion in the<br />

design of our systems and is also guaranteed in the case<br />

of <strong>Oerlikon</strong> <strong>Barmag</strong>’s industrial yarn systems: the crossflow<br />

quenching is characterized by simple maintenance and<br />

remarkably easy access to the spinning heads and yarn path.<br />

Radial quenching system<br />

Radial quenching systems offer a very uni<strong>for</strong>m quenching of<br />

the filament bundle ensuring a significantly improved single<br />

filament quality compared to X-flow. Due to the uni<strong>for</strong>m<br />

physical properties of the individual filaments, this is the<br />

quenching principle to achieve outstanding yarn quality.<br />

For HMLS processes with a high number of filaments the<br />

radial quenching system is an option. Its major advantage in<br />

terms of preserving natural resources is the extremely low air<br />

consumption.<br />

<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

31


Godets<br />

<strong>Oerlikon</strong> <strong>Barmag</strong> godets are custom-developed components <strong>for</strong> manmade fiber <strong>production</strong>. Continual<br />

innovations in the areas of design, process, and safety fulfill the ever increasing demands of ever faster<br />

processes and higher denier processes. Our godet families are renowned <strong>for</strong> their countless productive<br />

details. Their technological properties make it possible to achieve outstanding results in a huge variety<br />

of processes.<br />

High productivity and competitiveness are ensured thanks to<br />

the following basic requirements:<br />

- Robust design;<br />

- Achievable high process speeds;<br />

- Low-energy consumption <strong>for</strong> HF godets;<br />

- Reduced maintenance times;<br />

This all makes the <strong>Oerlikon</strong> <strong>Barmag</strong> godet family the<br />

suitable choice <strong>for</strong> all manmade fiber processes.<br />

Cold Rolls<br />

With the increasing amount of yarn ends per position, a<br />

smooth yarn path is becoming more and more important. To<br />

ensure a proper pretension of the yarn, the <strong>Oerlikon</strong> <strong>Barmag</strong><br />

take-up <strong>for</strong> more than 6 ends uses a cold roll duo with<br />

220mm diameter.<br />

HF godets<br />

To fulfill the special demands made on godets in industrial<br />

yarn spinning processes – significant drawing and shrinkage<br />

<strong>for</strong>ces plus utmost uni<strong>for</strong>m temperature profiles – our godets<br />

have been optimized both <strong>for</strong> conventional industrial yarn<br />

32 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

processes and HMLS processes. The modular godet series<br />

is tailored to the latest industrial yarn processes and covers<br />

all possible product ranges up to 24 ends or a denier range<br />

up to 18,000 den per position. With these components, every<br />

take-up is tailored to the customer’s demands. High-speed<br />

bearings with long service lives, using the Barolub lubrication<br />

system, and low power consumption are further benefits.<br />

Lower energy consumption<br />

Compared to other godet heating concepts, the HF principal<br />

has 20% lower power consumption than 50-Hz heat pipe<br />

systems. This results from the skin effect, which directly<br />

takes the energy to the location that has to be heated.<br />

Furthermore, the HF technology allows a significantly more<br />

compact godet design. For the same power output, the<br />

godet shell diameter can be reduced by 40 mm.<br />

For this reason, the HF godet family easily fulfills the requirements<br />

of the e-save label. The energy savings reach<br />

20-30%, even with high numbers of yarn ends per position.<br />

Lower energy consumption also reduces the investment in<br />

the A/C system, power distribution units, etc. This is further-


more supported by the power management, which ensures<br />

a uni<strong>for</strong>m distribution of the maximum energy load at startup<br />

of a take-up position. With the lower heat loss of godets<br />

plus the water-cooled electrical control system, the power<br />

consumption in the A/C system can also be significantly<br />

reduced.<br />

Technical data<br />

R220-<br />

400V60<br />

HFO220-<br />

400V60<br />

Digital control <strong>for</strong> user-guided operation<br />

All godet families are integrated in an interconnected<br />

control and drive system. The asynchronous motors are<br />

individually speed controlled by digital frequency inverters.<br />

The temperature control of the multizone heaters is also<br />

operated digitally. This guarantees an extremely easy,<br />

time-saving menu-controlled operation.<br />

Economic maintenance<br />

Extended maintenance cycles result in higher machine efficiency<br />

and increased productivity <strong>for</strong> the customer. Special<br />

benefits include the easy machine assembly/disassembly<br />

with the aid of flange mountings, plug-in connections and a<br />

decrease of individual parts by 50%. This results in a significant<br />

reduction in maintenance costs.<br />

Dependable quality at high output rates<br />

Stable operation, even at highest process speeds, is<br />

guaranteed by a fail-safe design principle and components<br />

that are uncompromising with regard to safety. This includes<br />

solid steel shells with no built-in parts as well as the drive<br />

motor and speed monitoring.<br />

The robustness of the latest bearing arrangement is specifically<br />

designed <strong>for</strong> ultra-high <strong>for</strong>ces and bearing load to<br />

achieve the max. lifetime and reliability of the hardware.<br />

HFO220-<br />

400V70<br />

HFP250-<br />

535V45<br />

HFP250-<br />

535V70<br />

speed [m/min] 350 - 6,000 350 - 6,000 350 - 7,000 400 - 4,500 400 - 7,000<br />

diameter [mm] 220 220 220 250 250<br />

length [mm] 400 400 400 535 535<br />

temperature max. [°C] – 250 250 260 260<br />

<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

33


ACW<br />

Especially designed <strong>for</strong> industrial yarn applications, our winders offer a high level of flexibility and<br />

profitability. Their wide operation window and robust design makes them a reasonable investment.<br />

The ACW winder makes it possible – with two winders – to<br />

wind up to 2 x 12 ends per position. Depending on the necessary<br />

package weight, the ACW winder series is suitable <strong>for</strong><br />

manufacturing in the low-, medium- and high-denier ranges,<br />

which are required <strong>for</strong> industrial yarns. For example, the lowdenier<br />

<strong>IDY</strong> winders cover a product range from 50 to 600<br />

den, while the high-denier winders cover a range from 200<br />

den to 6,000 den per end.<br />

Yarn quality<br />

Packages wound using the ACW are of excellent quality.<br />

The full package protection feature ensures fluff-free packages.<br />

A high quality take-off in downstream processing<br />

is guaranteed as a result of the possibility of varying the<br />

34 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

contact pressure along the entire length of the package as<br />

well as the perfect package build up by the Helicont system<br />

and step precision winding programs tailored <strong>for</strong> the specific<br />

denier ranges. As a result of the electrically driven bailer rolls,<br />

the shape of the packages can be influenced, hence enabling<br />

a high quality level in downstream processing. All yarn<br />

guiding elements are designed with the latest low friction<br />

surfaces ensuring the highest yarn quality level. A sensorcontrolled<br />

transfer tail device guarantees 100% uni<strong>for</strong>mity of<br />

the transfer and the end locator bunch.


Efficient operating<br />

The extended parking time diameter up to 210 mm allows<br />

more relaxed doffing, as the time window in which doffing<br />

has to be carried out has been considerably expanded. In<br />

the development of the new ACW: the designers have also<br />

taken the operator into consideration; the noise level has<br />

been significantly reduced with the BIROTOR / multi stroke<br />

traverse motion unit (MST).<br />

The semi-automatic string-up device simplifies the stringup<br />

process <strong>for</strong> the operator, hence improving efficiency by<br />

ensuring a fast and reliable string-up.<br />

Cost advantages<br />

The ACW winder series designed <strong>for</strong> <strong>IDY</strong> offer cost competitive<br />

<strong>production</strong> by supplying en<strong>for</strong>ced components <strong>for</strong> <strong>IDY</strong><br />

products up to 6,000 den per end or up to 16,000 den per<br />

winder. The robust design leads to:<br />

- High reliability;<br />

- Low maintenance requirements;<br />

- Long lifetime;<br />

- High utilization rate.<br />

Technical Data<br />

Process Winder Type Speed range<br />

[m/min]<br />

Design<br />

The ACW <strong>IDY</strong> winder series is specially designed <strong>for</strong> the<br />

high demands of the industrial yarn process. The increasing<br />

requirements <strong>for</strong> higher deniers and better yarn strength<br />

currently do not permit the use of a simple upgraded textile<br />

winder in industrial yarn processes. For this reason, the<br />

ACW-IY series is designed with a new strong birotor system<br />

with strong gears and robust birotor wings.<br />

Smooth surfaces and the carefully considered layout of the<br />

components ensure that the ACW is a maintenance-friendly,<br />

easy-to-clean unit.<br />

Denier range<br />

per end<br />

[den]<br />

Max denier<br />

on winder<br />

[den]<br />

Chuck<br />

Diameter<br />

[mm]<br />

Stroke<br />

[mm]<br />

<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

Bobbin<br />

Volume<br />

[dm³]<br />

at 360 mm<br />

Low Denier <strong>IDY</strong> PET ACW4IT-1500/12 2500-4000 50- 600 7200 110 95 10,2*<br />

Low Denier <strong>IDY</strong> PA ACW6IT-1500/12 2500-6000 50- 600 7200 125 95 9,9*<br />

HT / X-SLS PA & PET ACW4IY-900/3 2500-4000 1500-4000 9000 94 250 23,2<br />

HT / X-SLS PA & PET ACW4IY-1200/4 2500-4000 1000-6000 12000 94 250 23,2<br />

HT / X-SLS PA & PET ACW4IY-1200/6 2500-4000 200-2000 12000 94 170 15,7<br />

HT / X-SLS PA & PET ACW4IY-1600/8 2500-4000 200-2000 16000 125 170 14,7<br />

HMLS PET ACW7IY-900/3 2500-7000 1000-2000 6000 110 250 22,4<br />

HMLS PET ACW7IY-1200/4 2500-6600 1000-2000 8000 110 250 22,4<br />

*= Full Bobbin Diameter = 390mm<br />

35


Plant Operation Center (POC)<br />

POC – Plant Operation Center – is the all-embracing workflow management<br />

system from <strong>Oerlikon</strong> <strong>Textile</strong>. It is designed to detect and optimize the <strong>production</strong><br />

processes within a <strong>production</strong> stage, e.g. spinning or over all <strong>production</strong><br />

stages – starting with the raw material all the way through to the end<br />

product.<br />

Today, companies are confronted with challenges on all fronts: market requirements<br />

are becoming increasingly difficult to plan, pressure on margins is growing<br />

and the <strong>production</strong> environments of dynamic companies are becoming ever more<br />

complex. Within companies, data transparency, integrated processes and efficient<br />

resources planning are becoming success factors.<br />

The POC connects the <strong>production</strong> hall with the management and creates the<br />

link between the ERP system and the control center. The various POC modules<br />

offer you the ideal tools to further increase the productivity and efficiency of your<br />

systems. The software is modular, allowing you to create a customized system<br />

from the POC modules that is tailored to your precise requirements and that can<br />

be expanded at any time.<br />

With the available modules: Job disposition, Job View and Job Reports, the<br />

POC System functionalities can be expanded to establish the perfect link between<br />

the Plant Operation Center (POC) and the ERP (Enterprise Resource Planning)<br />

systems of the textile industry. With this technology, the POC really goes MES and<br />

is upgraded to a fully-functional Manufacturing Execution System.<br />

36 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong>


The POC creates transparency – the “Job Reports”<br />

module<br />

The status of manufacturing jobs is graphically displayed per<br />

spinning machine and/or per spinning position at all times.<br />

The screen shows comparable data of both current and<br />

completed jobs. The data is updated with each doff and is,<br />

there<strong>for</strong>e, extremely precise.<br />

The POC simplifies the workflow – the “Recipe<br />

Management” module<br />

Recipes define what will be produced. They include the complete<br />

list of all set-points or parameters that are important <strong>for</strong><br />

the product. During <strong>production</strong> planning, recipes are distributed<br />

to the <strong>production</strong> units.<br />

The POC increases efficiency – KPI (Key Per<strong>for</strong>mance<br />

Indicator) in a nutshell<br />

The latest addition to the POC gives users the com<strong>for</strong>ting<br />

feeling of being in<strong>for</strong>med at all times and in all places. Highlycondensed<br />

in<strong>for</strong>mation on the <strong>production</strong> systems can be<br />

accessed on mobile devices using apps.<br />

<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

37


SUN – Service UNlimited<br />

Getting you to the top<br />

What are your expectations when you are deciding on new<br />

product ranges and equipment <strong>for</strong> your textile business?<br />

Do you really want to have several providers to manage the<br />

complex manufacturing processes you need to control? And<br />

can you risk facing the situation that after a few years your<br />

investment may be virtually worthless?<br />

We at <strong>Oerlikon</strong> <strong>Textile</strong> are convinced that you shouldn‘t<br />

accept any of these limitations. This is the reason why<br />

<strong>Oerlikon</strong> <strong>Textile</strong> has devised SUN – Service UNlimited – the<br />

new service initiative that our Customer Support offers with<br />

its brands <strong>Oerlikon</strong> <strong>Barmag</strong>, <strong>Oerlikon</strong> Neumag, <strong>Oerlikon</strong><br />

Schlafhorst and <strong>Oerlikon</strong> Saurer to all its clients who require<br />

more than just service. SUN is a bundle of differentiated<br />

services that add real value to your <strong>Oerlikon</strong> <strong>Textile</strong> hardware<br />

and your daily business in a flexible way.<br />

Partnering <strong>for</strong> per<strong>for</strong>mance<br />

<strong>Oerlikon</strong> <strong>Barmag</strong> Service offers you a broad range of products<br />

and services to achieve your objectives - faster return<br />

on investment, shorter downtimes and process support.<br />

Based in Remscheid, a pool of highly qualified employees<br />

equipped to react fast and efficiently to the most varied<br />

customer demands. From erection and start-up to process<br />

consulting – our team of experts is waiting to support you.<br />

Moreover, in line with “think globally, act locally”, our worldwide<br />

network of service stations will always reach you –<br />

wherever you are. Local repair shops and on-site workshops<br />

at your <strong>production</strong> plant are characteristic of our service<br />

philosophy.<br />

Our R&D center at <strong>Oerlikon</strong> <strong>Barmag</strong>’s headquarters in<br />

Remscheid is equipped with ten modules <strong>for</strong>ming closed,<br />

self-sufficient units with a total of ten spinning plants on various<br />

levels. All modules can be independently-operated in<br />

accordance with the respective process requirements. The<br />

texturing R&D center at <strong>Oerlikon</strong> <strong>Barmag</strong>’s texturing equipment<br />

hub in Suzhou provides all currently available <strong>Oerlikon</strong><br />

<strong>Barmag</strong> draw-texturing machine types as well as facilities to<br />

evaluate process and machine per<strong>for</strong>mance supported by<br />

our experienced team of engineers. At both locations, customers<br />

can test their raw materials and products or develop<br />

new applications under optimum overall conditions.<br />

www.myoerlikon.com – access to success<br />

The my<strong>Oerlikon</strong> customer portal is up to date at all times,<br />

24 hours a day and throughout the year. The customer portal<br />

has a clearly arranged and uni<strong>for</strong>m website covering all busi-<br />

38 <strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

• Main <strong>Oerlikon</strong> <strong>Textile</strong> Service<br />

Network Stations plus more<br />

than 120 agencies worldwide<br />

ness units and their respective product lines. Our customers<br />

have online access to the latest documentation, tailored to<br />

their specific machines.<br />

The troubleshooting manual permits quicker and more efficient<br />

alleviation of problems via direct links. The SECOS<br />

e-Commerce system, well-known worldwide, is completely<br />

integrated. The Engineering tool supports and accompanies<br />

the entire engineering process from the concept to the<br />

turn-key plant. Innovative ideas and new solutions are added<br />

continuously. The latest encryption technology guarantees<br />

the maximum data security at all times.


<strong>IDY</strong> solutions – <strong>Oerlikon</strong> <strong>Barmag</strong><br />

39


<strong>Oerlikon</strong> <strong>Barmag</strong><br />

Zweigniederlassung der<br />

<strong>Oerlikon</strong> <strong>Textile</strong> GmbH & Co. KG<br />

Leverkuser Straße 65<br />

P.O. Box 11 02 40<br />

42862 Remscheid<br />

GERMANY<br />

Phone +49 21 91 67-0<br />

Fax +49 21 91 67-12 04<br />

www.oerlikontextile.com<br />

info.barmag@oerlikon.com<br />

<strong>Oerlikon</strong> <strong>Textile</strong> Inc.<br />

8801 South Boulevard<br />

P.O. Box 70 46<br />

Charlotte N.C. 28241<br />

U.S.A.<br />

Phone +1 704 910 42 68<br />

Fax +1 704 910 42 09<br />

info.charlotte@oerlikon.com<br />

The in<strong>for</strong>mation supplied in this<br />

brochure is <strong>for</strong> guidance only.<br />

We reserve the right to modify it<br />

at any time.<br />

OBA 208 e / 8/2011<br />

Studio 45 / Köllen Druck & Verlag, Bonn<br />

Subject to changes<br />

<strong>Oerlikon</strong> <strong>Textile</strong> Far East Ltd.<br />

Room 2806<br />

China Resources Building<br />

26 Harbour Road, 28 / F.<br />

Wanchai, HONG KONG<br />

P.R.CHINA<br />

Phone +852 28 27 43 14<br />

Fax +852 28 27 52 50<br />

info.textile.hk@oerlikon.com<br />

<strong>Oerlikon</strong> <strong>Textile</strong> India Pvt. Ltd<br />

Empire Industries Complex<br />

414, Senapati Bapat Marg<br />

Lower Parel (West)<br />

Mumbay-400013<br />

INDIA<br />

Phone +91 22 6652 7900<br />

Fax +91 22 6652 7901<br />

management.bom@oerlikon.com

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