Solutions for IDY production - Oerlikon Barmag - Oerlikon Textile
Solutions for IDY production - Oerlikon Barmag - Oerlikon Textile
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