Solutions for POY manufacturing - Oerlikon Barmag - Oerlikon Textile

Solutions for POY 

manufacturing

As creative as the market 

Oerlikon Barmag, a division of 

Oerlikon Textile GmbH & Co. KG 

with sites in Remscheid, Chemnitz, 

Wuxi and Suzhou (both 

People’s Republic of China), was 

founded as Barmag AG in 1922. 

The company is the world market leader 

for spinning systems and equipment 

for manmade fibers, such as polyester, 

nylon and polypropylene, and texturing 

machines and – as a service provider – 

offers engineering solutions for the 

entire textile value added chain. 

High-tech from the market leader 

Its core competencies also include the 

production of the associated components 

for manufacturing manmade 

fibers, such as extruders, winders, 

pumps and godets. As a future oriented 

company Oerlikon Barmag’s research 

2 POY solutions – Oerlikon Barmag 

and development is driven by the idea 

of energy-efficiency and sustainable 

technologies. With the expansion of the 

product range to include poly-condensation 

systems and their key components, 

the company now caters to the 

entire process – from the monomer all 

the way through to the textured yarn. 

At your service 

The primary Oerlikon Barmag markets 

are Asia, and China and India in 

particular, as well as the Middle East 

and Europe. Correspondingly, the 

company – with its approximately 

1,600 employees – has a worldwide 

presence in 120 countries as part of 

the Oerlikon Textile network of production, 

sales and distribution and service 

organizations. At the Oerlikon Barmag 

R&D Center – the largest of its kind in 

the world – within the company’s head- 

quarters in Remscheid, highly-qualified 

engineers and technicians develop 

innovative and technologically-leading 

products for tomorrow’s world. 

Oerlikon Barmag machines and components 

rely on a large number of 

registered trademarks and international 

patents.

Table of contents 

Plant engineering 4 

POY spinning solutions 6 

e-save – Energy saving and more 8 

Process solutions 10 

Key components 16 

Extrusion equipment 18 

Pumps 19 

Mixing and metering in polymer processing 20 

Spinning head series 22 

Spin packs 23 

Quenching systems 24 

WINGS 26 

Plant Operation Center (POC) 28 

Downstream process 29 

SUN – Service Unlimited 30 

POY solutions – Oerlikon Barmag 

3

Plant engineering 

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

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

network form a solid basis and the perfect prerequisites for Oerlikon Barmag as a solutions provider. 

Many texturizers depend on the import of POY which means 

that they have little influence on delivery times or on yarn 

quality. Having your own spinning equipment, however, 

opens up the opportunity to produce yarn independent of 

POY deliveries and to determine and control the yarn quality. 

Thus, it is possible to quickly and flexibly react to changes in 

the market. 

A harmonized chain of polycondensation, spinning and 

texturing machines allows efficient production which results 

in an increase of added value for the customer. Furthermore, 

Oerlikon Barmag will cater for a harmonization of all machines 

and lines in an optimal way and will provide the 

respective know-how. 

In plant engineering and construction, the term plant design 

means turnkey construction. This means that starting from 

the feasibility study through to the implementation of projects, 

the customer will receive all services from a single source. 


Oerlikon Barmag plant engineering delivers the following 

services: 

- feasibility study 

- consulting services 

- engineering services 

- basic and detailed engineering 

- guarantees for product and production 

Examples for engineering services are: 

- project management 

- plant layout and process engineering 

- machinery engineering 

- electrical and instrumentation engineering 

- piping engineering 

- polycondensation 

Oerlikon Barmag plant engineering looks after the complete 

processes, from the CP to the DTY machine, and includes 

chip handling, auxiliary plants, utility plants, general electrics 

as well as the respective documentation.

A selection of reference projects 

Engineering is one of the three supporting columns of Oerlikon Barmag’s solutions philosophy. In 

combination with cutting-edge technology and a comprehensive global service offering, engineering 

meets customer demand for an overall solution from a single source. 

A choice of projects demonstrates Oerlikon Barmag‘s expertise in the challenging field of plant 

engineering 

Project: The project covers a Polyester POY direct spinning 

system from polycondensation to winding. The polycondensation 

has a capacity of 100,000 tons per year. The spinning 

section consists of 6 lines with 24 positions at 10-end/ 

20-end. For winding, the yarn producer relied on WINGS, 

the new Oerlikon Barmag winder with the drawing zone 

included. 

Location: India 

Start up: Mai 2009 

Scope of supply: 

- Polycondensation 

- Transfer line from Polycondensation to spinning 

- spinning, take-up 

Engineering & Construction: 

- Basic engineering 

- Detail engineering 

- Supervision of erection & start-up 

Project: The project covers a Polyester POY spinning 

system from chips drying system to winding. The spinning 

section consists of 2 lines with 8 positions at 10-end. 

Location: Belarus 

Start up: 2009 


- Air conditioning system 

- Chips drying and chips conveying system 

- Chips / masterbatch dosing system 

- 2 x 4 position PET POY spinning lines, take-up 

- Accessories & utilities 

Engineering & construction: 


- Detail engineering 


Project: Dyed PET textile yarn with guarantees 

Location: Vietnam 

Plant type: 24 positions, 10-end PET POY extrusion 

spinning plant, with yarn guarantee 

Start up: October 2006 


- Chips conveying & storage, chips crystallisation & drying 

- Extruder, spinning, take-up and accessories 

- Air conditioning system 

- Accessories & utilities 

Engineering & construction: 


- Detailed engineering 



5

POY spinning solutions 

For more than 50 years now, POY yarns made from polyester and 

polyamides have formed the majority of textile fi laments and hence 

also the most important sector for all textile yarn manufacturers 

across the globe. In this period, a continual increase in systems 

productivity has been noticeable with rises in the number of yarn 

ends, from originally 2 ends to currently up to 20 ends per position. 

Yarn manufacturers – whether providers 

of standard qualities or niche 

products – are faced with increasing 

pressure on effi ciency. In demand are 

methods and means that increase the 

performance and quality of the production 

process. This is the starting point 

for WINGS. 

The WINGS concept 

Developed with the objective of increasing 

the productivity and effi ciency 

of POY systems, the revolutionary 

concept bears the solution in its very 

name: Winding INtegrated Godet Solution 

– in short WINGS. The winder as 

a complete take-up machine removes 

the spatial separation of godets and 

winders common today. 

Faster 

In conventional spinning systems, the 

drawing unit and the take-up unit form 

two levels beneath the spinning unit, 

so that the yarn string-up needs to be 

carried out by two operators. In contrast, 

WINGS can be completely operated 

from fl oor-level and all elements 

are laid out at eye level. Consequently, 

this signifi cantly reduces the time required 

for yarn string-up by more than 

50%; time in which top-quality POY 

yarn – and not waste – can be produced. 

Furthermore, this simplifi cation 

of the string-up process considerably 

reduces the risk of operator errors. 

WINGS simplifi es and shortens the 

installation of the system. The entire 

WINGS take-up concept is delivered 

from Germany as a completely pre- 


installed and tested unit. All that is 

required onsite is the connection of 

the power and compressed air supplies. 

This concept allows a signifi cantly 

earlier production start compared to a 

conventional POY line. 

Furthermore, there are considerably 

fewer requirements for the building 

in the case of the WINGS concept. 

Conventional layouts require the elaborate 

installation of fl oor tracks and the 

almost millimeter-accurate alignment of 

the drawing unit and winder. As a result 

of the new 3-point-concept, spinning 

positions equipped with WINGS make 

no special demands on the evenness 

of the fl oor and hence provide optimal 

process and, hence, product quality 

even in the case of slight fl oor unevenness, 

therefore entirely dispensing with 

costs for accurate alignment. 

Better 

The new WINGS concept has been 

systematically geared towards reducing 

the cord angle within the drawing unit. 

Insofar as is prudent, points with a high 

wrapping angle have been equipped 

with rotating and hence friction-free 

yarn guides. The sum of all defl ection 

angles in the drawing unit is now approx. 

7°.This is an absolute reduction 

of 21° compared to conventional POY 

drawing units. 

Therefore, yarn manufacturers are 

able to spin considerably more even 

yarns with WINGS. For example, the 

CV% values for tenacity and elongation 

can be reduced by up to 40% in com- 

parison to conventional POY drawing 

units. 

More energy conscious 

Due to its highly effi cient intermingling 

concept, the new WINGS tangle jet 

enables further savings in comparison 

with other POY winding systems. In 

addition to the waste incurred for normal 

string-up processes, the reduced 

string-up times for WINGS also require 

less compressed air. This results in 

energy savings of 25-45 %. 

More frugal 

WINGS is an autonomous unit with an 

integrated control cabinet. Removing 

the drawing unit offers greater freedom 

in the positioning of the machines. 

Here, manufacturers can plan conventional 

layouts so as to create more 

space for air-conditioning channels, for 

example. 

However, WINGS also permits a considerably 

tighter layout of the spinning 

unit. The space requirement is reduced 

by at least 25% compared to conventional 

systems. A new spinning unit 

building for a given production capacity 

can hence be much more compact, allowing 

companies to reduce the costs. 

And integrating WINGS into an existing 

spinning plant building offers benefi ts 

in terms of the reduced height of the 

components.


7

e-save – energy saving and more 

Think e-save and reduce your production costs! 

Under this motto Oerlikon Barmag started promoting 

energy-conscious machines and components 

in 2005. The combination of high-performance 

machines and systems, high flexibility and low 

conversion costs is enabling manufacturers to be 

successful market players. 

The focus of e-save is on the reduction of the conversion 

costs. In 2005, Oerlikon Barmag developed and launched 

the e-save label, which is awarded to those components 

whose energy consumption has been significantly reduced 

compared to standard components available on the market. 

Demands and inquiries from our customers have encouraged 

us to systematically further research and develop the 

approaches we have already taken. Like a stone thrown into 

a lake, e-save is creating ever more positive repercussions. 

In addition to energy-efficient components, Oerlikon Barmag 

offers resource-minimizing solutions in many areas. 

Energy and environmental costs are also a not inconsiderable 

factor in POY production systems. Today, they already 

cause up to a third of the conversion costs of a spinning 

plant. All savings in this area benefit the local environment, 

while energy and resource efficiency are becoming ever 

more important locational factors on a global level. 

8 POY solutions – Oerlikon Barmag

There are numerous possibilities for sustainably lowering the 

consumption of valuable resources. Firstly, there are energyoptimized 

components, for example Oerlikon Barmag’s SP8x 

spinning beam, which consumes more than 40% less energy 

than other more common designs. In a POY spinning system 

with 144 positions, this generated an annual saving of 

approx. U$ 90,000. 

Reducing the consumption of controlled-processed air is 

an important objective of the EvoQuench. Radial quenching 

consumes 60-80% less air than cross-flow quenching – 

and can be used for manufacturing microfilaments and 

commodity yarns of up to 3 dpf. 

Multi-filament spinning saves energy 

However, the utilization of efficient components is only one 

step on the path to creating smart production processes. 

Restricting the examination to the spinning system alone 

does not take important factors into account. Within this 

context, the multi-filament capability should definitely be 

considered an energy-saving factor. Spinning 20-end POY 

using a spinning beam with DIO spinnerets and a quenching 

unit on 2 take-up positions is therefore considerably more 

efficient than two 10-end spinning positions. 

A decisive associated factor that influences the overall 

energy consumption is the air-conditioning system. Drives, 

heating systems, components that come into contact with 

the melt as well as the filaments radiate heat. If this heat 

radiation is reduced by means of excellent insulation, the 

air-conditioning system can be small, hence itself using less 

energy. 

Oerlikon Barmag – with its focus on innovation and 

technological leadership – provides a variety of machines, 

components and solutions that stand out through their 

excellent resource efficiency and thus easily fulfill the 

requirements defined by the e-save label. 


9

Process solutions 


Our customers can benefi t from the comprehensive optimization 

of single processes along the textile value chain. Our big advantage 

is the fact that Oerlikon Textile serves the world’s largest 

spread of applications in the textile machinery industry. Oerlikon 

Barmag offers complete production lines from a single source – 

to offer the best possible solution – and we also work together 

with partners if special external expertise is necessary. 

Technology and support going hand in hand 

Innovative machines and systems are just part of the story. 

Oerlikon Barmag’s process solutions turn machines into teams. 

They integrate production processes and match every item of 

equipment perfectly to the next. Customers profi t from Oerlikon 

Barmag’s comprehensive process know-how along the polycondensation, 

spinning and texturing steps in the textile value chain. 

Oerlikon Barmag’s solutions take a big weight off customers’ 

minds. Oerlikon Barmag’s one-stop shop covers everything from 

fi nance through to turnkey plants. Top machinery, comprehensive 

process skills, professional advice and service are all in the 

package.


11

Polyester POY 

The optimized processes for manufacturing polyester 

POY on Oerlikon Barmag systems guarantee 

the best possible combination of number of ends 

and package weight. DTY and other downstream 

processes can be run at extremely high take-up 

speeds as a result of the excellent yarn evenness 

achieved. The best CV% values as well as AA-quality 

yarns are standard. 

The production process with 20 ends can be carried 

out using the hydraulic-split procedure. However, the 

requirements of a high yarn-to-yarn titer evenness require 

the double-in-one (DIO) technology. With this technology, 

two separate polymer melt flows are led through a package 

completely separately using their own spinning pump. This 

enables titer evenness identical to single packages while 

requiring 30% less space. 

The optimized production process is designed for low 

conversion costs as a result of low investment costs and – 

in comparison to standard spinning systems – low space 

requirements within the spinning unit. The yarn is wound 

onto individual WINGS machines, hence allowing the system 

to produce a high number of ends at high speed, while still 

permitting a package volume of 16.8 dm³. This also ensures 

full bobbin rates as the yarn path to each winder is completely 

separated. The process was optimized to the lowest 

angle of deflection, which enables low POY CV% values. For 

this reason, the material can handle the highest speeds in 

texturing and in further downstream processes. 

Process 10 ends 20 ends 

Titer final 30 - 400 den 30 - 200 den 

Single filament titer 0.3 - 6.3 dpf 0.5 - 5.0 dpf 

Filament count 12 - 384 18 - 144 

Ends per position 10 2 x 10 

Mechanical speed 2500 - 4000 m/min 2500 - 4000 m/min 

Chuck length 1500 mm 2 x 1500 mm 

Volume 16.8 dm³ 16.8 dm³ 

Extruder or direct spinning 

Spinning beam series SP8x (z) SP8x (z) 

Winder type series WINGS 2 x WINGS 

Quench type series EvoQuench (z), cross-flow EvoQuench (z), cross-flow 


Microfibers 

There are different processes available for manufacturing 

polyester microfibers: cross-flow half-pipe quenching permits 

titers of between 75 and 150 den, whereby the titer of the 

individual filament lies between 0.5 and 1.5 dpf. 

Alternatively, the process using EvoQuench quenching 

allows for finer titers of between 30 and 400 den. This 

process enables titers for the individual filament to be 

between 0.34 and 3 dpf. Up to 288 ends can be manufactured 

using this technology. 

EvoQuench quenching reduces the quench air consumption 

by around 60% compared to cross-flow quenching, hence 

achieving considerable savings in the conversion costs.


© VAUDE 

13

Polyamide 6 POY 

The Oerlikon Barmag process for the production 

of polyamide 6 POY opens up a surprisingly broad 

denier range. Furthermore, this process is characterized 

by high productivity and excellent prerequisites 

for manufacturing polyamide 6 microfibers. 

The design of the draw unit can very flexibly cover 

all product areas. 

And once again the best CV% values and AA-quality yarn 

are standard here – as in the case of all our processes. 

Polyamide 6.6 POY 

Approximately 80% of the world’s yarn producers 

use Oerlikon Barmag systems for manufacturing 

polyamide 6.6. This shows to what extent we have 

mastered the process. 

Specially designed extruders, spinning units and take-ups for 

the PA6.6 process permit high productivity and a broad denier 

range. Hence, this process is also unrestrictedly suitable 

for the production of PA6.6 microfibers. 

And – as always – we also guarantee the best CV% values 

and AA yarn qualities with this process. 


Process 

Titer final 20 - 150 den 

Single filament titer 1.0 - 4.2 dpf 

Filament count 3 - 96 

Ends per position 12, 2 x 12 

Mechanical speed 3500 - 4800 m/min 

Chuck length 1500 mm 

Volume 13.0 dm³ 

Extruder spinning 

Spinning beam series SP8x 

Winder type serie WINGS, 2 x WINGS 

Quench type series cross-flow 

Process 

Titer final 20 - 100 den 

Single filament titer 1.0 - 4.2 dpf 

Filament count 3 - 96 

Ends per position 8 

Mechanical speed 2500 - 4800 m/min 

Chuck length 1200 mm 

Volume 16.8 dm³ 

Extruder spinning 

Spinning beam series SP4x 

Winder type series WINGS 

Quench type series cross-flow


15

Key components 


First-class solutions comprise first-class machine systems manufactured 

using first class components. This commitment determines the 

quality of our components. 

Oerlikon Barmag’s product range comprises extruders all the way 

through to the winding systems for all components within a spinning 

plant. As a systems constructor, we know the importance of the 

individual process steps and each partial component. 

For this reason, all Oerlikon Barmag components have their own 

success story: we have been designing and constructing extruders 

since 1958, the company has more than 50 years of experience in 

building pumps and has supplied in excess of 100,000 winders 

throughout the world since 1972. 

We are not content with merely tried-and-tested design – our mission 

statement is the continual further development of all components to 

achieve even greater efficiency and even better technical solutions 

for our customers.

The 100,000th winder 

delivered by Oerlikon 

Barmag has been goldplated. 


17

Extrusion equipment 

Oerlikon Barmag spinning extruders excel in gentle 

and homogeneous melt production and are noted for 

cost effectiveness, reliability, and long service life. 

The utilisation of top-quality, low wear materials – in particular 

for the extruder cylinders and the extruder screw – ensure 

long-term, error-free operation. The screw geometries with 

special homogenizing components have been determined 

to ensure short dwell times, in order to keep the thermal and 

mechanical loads of the melt to a minimum – the basis for 

excellent melt and hence first-class yarn quality. 

Oerlikon Barmag extruders fulfill the energy saving requirements 

for e-save. The e-save label is given to systems and 

components that have energy consumptions significantly 

lower than standard equivalent systems and components 

available on the market. 

Throughput capacity 

24D 4E 6E 7E 9E 10E 12E 15E 17E 

PET norm. kg/h 70 130 200 300 400 520 820 1120 

PA6 norm. kg/h 40 80 125 200 270 350 550 750 

PA6.6 norm. kg/h 40 70 120 180 240 315 - - 

30D 4E 6E 7E 9E 10E 12E 15E 17E 

PET norm. kg/h 90 160 260 380 500 660 1000 1380 

PA6 norm. kg/h 45 90 145 230 310 400 630 - 

PA6.6 norm. kg/h 45 90 140 200 280 380 - - 


Oerlikon Barmag extruders are chracterised by a good 

barrel insulation resulting in energy savings and a low surface 

temperature on the barrel jacket. The two-step spur gear 

guarantees long service life and smooth running. The feed 

area for inert gas or vacuum is designed to prevent oxidation 

of the polymer, thus ensuring trouble free spinning. Specially 

matched screw and barrel materials result in good sliding 

properties and low wear. 

Air-cooled extruder series 

These are the perfect choice for processing PETP, PA6, 

PA66, PP and other spinning polymers in all viscosity ranges 

for all man-made fiber requirements. An output ranging from 

3 kg/hr to 1,500 kg/hr is possible. This extruder version 

includes a fine-graduated program with screw diameters 

from 30 to 175 mm, and screw lengths of 30 L/D or 24 L/D. 

Further, the specifically-cooled barrel sections expand the 

production window. 

The additional feature offered for this series is the control 

cabinet, which is integrated into the extruder frame. This version 

transforms our well-established model into a compact 

unit with significantly less wiring. 

All versions are available with or without a cooling system for 

the barrel. An injection system introducing master-batches 

or liquids into the polymer stream at various locations for 

customized fiber characteristics is also available.

Pumps in a spinning plant 

Polymer pumps – for the most demanding 

requirements 

Process stability and product quality are heavily influenced by 

the polymer in the manufacture of man-made fibers. As the 

leading manufacturer of man-made fiber systems, Oerlikon 

Barmag knows how the design of the individual systems 

components influences the quality of the polymer and hence 

the spinning process. 

Booster pumps build up the pressure which is required by 

the system – with a high degree of flexibility and reliability. 

Booster pumps in polymerization or polycondensation 

plants, also known as transfer pumps, receive the necessary 

supply pressure from the discharge pump. These are used 

to provide the necessary pressure for the downstream consumer 

units. These consumer units include spinning pumps, 

flat nozzles, perforated plates for granulation, etc. Frequently, 

the conditions within the system can also change, for example, 

through standstill of the downstream units. These 

demand flexibility; depending on the application even 

negative differential pressures can occur. Oerlikon Barmag 

booster pumps solve these tasks thanks to the universally 

applicable design of the bearing lubrication system. 

Spinning pumps – innovative and reliable 

The spinning pump is one of the key components of a 

spinning system. Even when used over many years of 

production, all Oerlikon Barmag spinning pumps guarantee 

consistent yarn quality, the most important factor in successful 

yarn production. 

The special advantages of Oerlikon Barmag’s planetary 

gear spinning pumps include: 

- optimal melt flow due to rheologically advantageous melt 

channels 

- highly polished melt channel surfaces, ensuring superior 

flow conditions 

- high-precision manufacturing methods, allowing for excellent 

running performance and stable melt exchange 

- specially designed relief grooves in the melt outlet area of 

the gears, for minimized compression forces and operation 

with few fluctuations in the flow. 

Together, these advantages translate into the uniformity of 

the melt streams. 

Spin-finish pumps – high-precision and maintenance-friendly 

with extreme durability 

The more even the application of the spin-finish liquid to the 

yarn, the better the yarn quality. A trailblazing design now 

sets considerably higher standards in terms of feeding 

accuracy, reliability and durability. 

The PROFIN series is designed for use with all commercially 

available types of spin-finish, from high, down to low oil 

concentrations. In addition, the production program includes 

pumps specifically tailored to handle corrosive spin-finish 

liquids. Identical connection dimensions of the PROFIN spinfinish 

pumps permit exchange with those of the previous 

series. 

PROFIN spin-finish pumps convince by 

- Long service life 

- Operator–friendliness 

- Operating stability 

- Quality management 


19

Mixing and metering systems 

More than 90% of the world’s textile polyester and 

nylon filaments are spun in raw-white. Dying the 

yarns or textiles takes place later in the form of 

package or piece dyeing despite the fact that these 

processes are in many respects inefficient. 

The energy requirements for heating the dye bath and subsequent 

drying of the dye product – in the case of package 

dyeing, we must also consider the rewinding – are high. The 

high consumption of water and chemicals and the associated 

volume of contaminated waste water have a negative 

impact on the environment. Furthermore, the dyeing process 

is time-intensive. 

e-save with spin-dyeing 

An alternative is the spin-dyeing of textile and industrial 

yarns. As the masterbatch is directly added and mixed into 

the polymer melt, no further process steps are required in 

the dye plant. The spin-dyeing requires only a fraction of 

the energy, the water, the processing time and the space 

needed for conventional dyeing processes. 

Feed options 

Additives can be fed into the polymer at various points. The 

appropriate point must be determined, taking flexibility and 

costs for each process individually into consideration. 

feed position 

extruder hopper 


upstream to 

3DD mixer attached 

to the extruder 

Additives and dyes for plastics are becoming an increasingly 

important part of the manufacturing process. The properties 

of the polymers can be extensively modified as a result of 

additives. The option of directly introducing these additives 

during the manufacturing process (e.g. fibers or films) provides 

a high degree of flexibility and increased efficiency. 

The dynamic, three-dimensional mixing principle has proven 

to be an excellent choice when feeding additives, dyes, 

stabilizers and other polymers. Pumps for liquid additives or 

compact combination of injection extruders with gear pumps 

are used for feeding. The systems can be integrated in various 

areas of the melt system. 

Powered 3DD mixer 

One or more additive flows can be added to the main melt 

flow upstream to the mixer. The constant changing of the 

rotor/stator groove allocation creates a dynamic 3-dimensional 

flow that includes both a longitudinal, dispersive and 

distributive mixing result. 

Technical data Powered 3DD mixer 

Type Ø 

(mm) 

7E-3DD 

10E-3DD 

15E-3DD 

17E-3DD 

20E-3DD 

22E-3DD 

upstream to 

separately- 

driven 3DD mixer 

upstream to 

Promix AC 

mixer pump 

max. main flow 

kg/h 

form of additive granulate melt; liquid additive melt; liquid additive melt; liquid additive 

flexibility 0 0 + ++ 

costs ++ + 0 0 

75 

105 

150 

175 

200 

225 

260 

500 

1000 

1400 

1800 

2300

Feed extruder with metering pumps 

These components are required whenever master batch 

melts need to be metered into the main melt flow under 

high pressure. Throughput volumes from 3 kg/h can be 

metered. 

3DD mixer as an extruder extension 

This mixing unit is attached to Oerlikon Barmag extruders as 

a screw and cylinder extension. The master batches to be 

added are either fed via the extruder hopper (granulate) or 

later into the mixing zone (melted up, liquid). The mixing zone 

can be separately heated or cooled. 

Powered 3DD mixer as a separate unit 

This unit is a hot melt extruder with a dynamic mixing function. 

Here, the pressure differential required for mixing is 

extensively compensated by the pressure build-up in the 

screw section. The speed can be selected in accordance 

with the mixing task. The melt temperature can be influenced 

by the air-cooled mixing cylinder. The mixer is designed for 

integration into melt distribution systems for larger throughput 

volumes (> 100 kg/h). Both melt and liquid mass flows 

can be fed in. 

Promix AC 

For customized feeding of additives or dyes (liquid) at the 

spinning position, this planetary gear pump offers an injec- 

tion function. To this end, the dynamic mixer works synchronous 

to the pump speed. Pumps with 3, 4, 5, 6, 8, 10 or 12 

outlets are available. 

Promix VS 

To be able to tend to the mixing and metering functions 

separately in terms of process, a unit with 2 separate drives 

for mixing and metering was developed. The unit can be 

integrated into spinning positions or upstream into the melt 

distribution system. 

Inject AC - metering system for liquid additives 

This system was developed for feeding liquid dyes and additives 

into plastic granulate (unpressurized) or polymer melt 

(pressurized). One metering pump is used for unpressurized 

feeding. 

When feeding under pressure, two metering pumps in series 

are used, whereby the first pump carries out the pressure 

build-up and the second the high-precision metering. The 

speeds of both pumps are set using an intelligent control 

system. 

The system can be completed with pressurized tanks with 

electrical filling height monitoring and valves. Valve technology 

enables fast dye changes using a rinse mode. 


21

Spinning head series SP8x 

First-class spinning heads make first-class yarns make first-class 

profits! The quality of the thread is determined during spinning. 

The manifold in an Oerlikon Barmag spinning line is specially 

optimized regarding melt residence time, drop in pressure 

and shear rate. It is characterized by: 

- flow-favorable melt distribution for excellent yarn uniformity 

along the spinning line; 

- high surface quality of the pipes ensures favorable melt 

flow behavior for superior quality right from the first day of 

production; 

- absolute dead spot-free design is a precondition for low 

break levels and high yields; 

- the overall distribution system is virtually maintenancefree. 

Oerlikon Barmag’s spinning head series covers the processes 

for textile and industrial yarns as well as home 

textiles even for processing critical materials like PA6.6 and 

new materials like PTT. In all cases the spinning head steam 

heating ensures excellent temperature uniformity. 

e-save with SP8x 

The Oerlikon Barmag SP8x spinning head concept unites 

the advantages of high-end melt quality. The design of the 

spinning head has considerably reduced the heat-radiating 

surface and simultaneously significantly improved the insulation. 

This has resulted in a more than 40% reduction in the 

heat-radiation in comparison to the SP5x system. In trials, 

this has revealed, for example, energy savings of more than 

200,000 kWh/year for a 36-position system. 


The SP8x spinning head ensures economic spinning processes 

with high product quality through its very even melt 

guidance system with optimized residence time. Furthermore, 

the shroud – which can be specifically adapted to the 

respective product on request – ensures an extremely high 

level of flexibility. The shroud is part of the heat transfer medium 

(HTM)-heated spinning head and guarantees extremely 

high temperature evenness without the additional energy 

requirements of an electrically-heated concept. This system 

also enables the production of microfilaments without loss 

of quality and productivity and excellent productivity for 

standard titers. 

Needless to say, the well-known self-sealing Oerlikon 

Barmag spin packs can also be used for this system. The 

rheologically-optimized melt distribution and uniform heating 

ensures that the good melt quality in the spinning head is 

also continued within the spin pack. 

Reduced spacing with zigzag 

In combination with the EvoQuench radial inflow quenching 

unit in zigzag layout, the SP8x is also available in a zigzag 

design. The reduced spacing in comparison to a standard 

EvoQuench and SP8x spinning head allows for a higher 

number of spin packs or bigger packs in the same position 

pitch. This option is available for 88 and 104 mm spin packs.

Spin packs 

Advanced spin pack 

Through continual further development of the spin packs, the 

spinneret surface has been increased by up to 25% while 

maintaining the same external dimensions. The throughput 

required for the spinning process can hence be achieved 

with a smaller spin pack diameter. The spinning head melt 

residence time reduces by 10%. 

The new design offers the following process benefits: 

- increased filament distance on spinneret for better filament 

cooling and fewer yarn breaks, especially for micro- 

fiber and high count; 

- large filter surface for higher throughput, compared to 

other spin packs with the same outer spin pack diameter; 

- large filter surface for longer spin pack operation time; 

- increased filament count (microfiber) compared to other 

spin packs. 

The advanced spin pack is available as the proven self sealing 

version, however, for the production of polyamide 6.6 we 

supply a forced sealing version. 

Double-in-one 

When looking at throughput, POY systems for small titers 

require a relatively high level of investment. The 20-fold 

Double-in-one (DIO) spinning plant concept has been able to 

considerably reduce the investment costs while maintaining 

yarn quality. 

The DIO concept, with two completely-independent spinnerets 

in one base, allows manufacturers to use approx. 

30% less space vis-à-vis single packages while retaining the 

titer evenness. Microfilaments with 20 ends can be efficiently 

manufactured if the DIO technology is combined with the 

EvoQuench system. 

Even yarn specialties can be economically manufactured 

with the optimal combination of DIO and quenching system. 

With two independently-operated take-up units and the 

systematic separation of the respective five DIO spinnerets 

within the quenching system and spin stack, each position 

is completely independent of the neighboring position 

in the same spinning head in the event of yarn breaks. This 

is evident in the fact that 20-end concepts can achieve full 

package rates which are the same as those for 10-end 

processes. 


23

Quenching systems 

The main task of the quenching system within the context of complex spinning processes is the even 

quenching of the liquid filaments at the exit of the spinneret. Oerlikon Barmag quenching systems 

supply a uniform, turbulence-free airflow for achieving excellent uster values. 

During the quenching process, each filament is supplied with 

the same amount of cooling air, hence ensuring defined 

crystallization and orientation of the polymer molecules as 

the basis for optimal uster, elongation and dyeability. For this 

reason, the quenching process has a decisive influence in 

achieving excellent yarn qualities in the synthetic filament 

manufacturing process. Moreover, all current processes are 

covered by this system. 

Quality assurance down to 0.3 dpf 

Oerlikon Barmag provides different quenching systems 

specially matching the customers’ needs: The standard 


cross flow quench system is suited for standard yarns higher 

than 0.5 dpf (denier per filament). The cross flow quench 

system with quench booster stabilizes the production of 

yarns in the 0.5 to 1 dpf range. 

For the production of super fine micro filaments (down to 

0.3 dpf) we recommend the EvoQuench system. This allows 

for a maximum of 388 single filaments per end. 10 ends per 

position ensure high productivity.

Cross flow quenching system – one unit for (almost) 

everything 

This quenching system is the number one choice for all 

commodity applications. Robust, easy to use, suitable 

for a broad range of titers and all standard polymers, the 

Oerlikon Barmag cross flow quenching system feels at 

home in almost all POY spinning processes. As a result of 

the specially constructed rectifier, which corresponds to all 

requirements in terms of even and laminar airflow, extremely 

high yarn qualities can be achieved. 

EvoQuench – something innovative from the 

technology leader 

In contrast to the cross flow, the air here is symmetrically 

guided from the outside of the thread bundle to the inside. 

This ensures optimal flow cooling of the thread along the 

entire length of the filament surface. The EvoQuench system 

was developed for micro-fiber yarns all the way down to 

0.3 dpf, but also covers a good range of commodity yarns. 

With more than 3500 installed positions the EvoQuench 

system is on its way to become a sales hit made by Oerlikon 

Barmag. 

EvoQuench zigzag 

A spinning system configured with the zigzag version of 

the EvoQuench quenching unit is extremely compact and 

simultaneously highly-efficient. When combined with an 88mm 

spin pack, for example, it can produce ten filaments of 

outstanding quality on a spinning position of just one meter 

in width. 

e-save with EvoQuench 

In the quenching unit, it is the consumption of controlledprocessed 

compressed air that is the criterion that determines 

the resource consumption and hence the conversion 

costs. Depending on the titer and dpf, Oerlikon Barmag’s 

EvoQuench unit reduces the air requirements by between 

70% and more than 80% compared to a cross-flow 

quenching unit. The air savings per spinning position add 

up to more than 20,000 m³ every year. 


25

On the WINGS of success 

WINGS means the integration of all relevant individual components in 

a conventional POY spinning position within a complete winding unit. 

More even yarn quality 

The parallel yarn path achieved with the WINGS concept 

with its considerably reduced wrapping at the static thread 

guides results in a minimized wrapping difference between 

the yarn exterior and interior. While the wrapping difference 

for conventional POY spinning plants is 28 degrees, WINGS 

reduces this to only 7 degrees. This guarantees a more even 

and hence an overall improved yarn quality within a winding 

position. 

Close to each other 

A novel “zigzag” layout enables considerably higher component 

density for winding positions within the production site 

as the spinning lines can be assembled in a denser layout. 

The component density and the lower height of WINGS – the 

result of dispensing with the operator platform prevalent in 

conventional POY spinning plants – offers considerable savings 

potentials for investments in land and buildings. This is a 

not inconsiderable factor when planning new factories. 

Child’s play 

WINGS is a plug & play unit. Assembly and commissioning 

with the completely installed and tested take-up unit are 

child’s play and can be carried out with minimum cost and 

time. 

Technical data 

version chuck tube take-up max. volume (dm 3 ) / stroke length (mm) 

length inner speed package 

Ø Ø 

mm mm m/min mm 8 ends 10 ends 12 ends 

Polyester 

WINGS 40T-1200/8 1200 94 2500 - 4000 440 17.1 / 120 

WINGS 40T-1500/10 1500 110 2500 - 4000 440 16.8 / 120 

Polyamide 

WINGS 48T-1200/8 1200 110 2500 - 4800 440 16.8 / 120 

WINGS 48T-1500/12 1500 125 3500 - 4800 440 13.0 / 95 


At eye level 

WINGS is at eye level. This means that the yarn can be 

strung-up by one person – whereby the normal string-up 

time of 3 minutes is now considerably reduced to 75 seconds 

and without string-up errors. Clear overview – clear 

control. 

Perfect DTY performance 

WINGS has a reliable ribbon distubring system which takes 

care of an optimal package construction irrespective of the 

diameter. Furthermore, the contact pressure control reduces 

the yarn break rate in the following texturing process by 

50 %. Optimized parameters setting avoids expecially 

bottom breaks. 

Energy conscious 

The WINGS concept reduces the energy consumption of the 

complete spinning system by remarkable 25 to 45 %. This 

comprises the necessary compressed air, the air conditioning 

as well as the energy consumption of the drawing zone.


27

Plant Operation Center (POC) 

The POC – Plant Operation Center – is the all-embracing 

workflow management system from Oerlikon Textile. It is 

designed to monitor and optimize the production processes 

within a production stage, e.g. spinning, or the 

entire value added chain – starting with the raw material 

all the way through to the end product. 

Today, companies are confronted with challenges on all 

fronts: market requirements are becoming increasingly difficult 

to plan, pressure on margins is growing and the production 

environments of dynamic companies are becoming 

ever more complex. Within companies, data transparency, 

The POC creates transparency – the “Job Reports” 

module 

The status of manufacturing jobs is graphically displayed at 

all times per spinning machine and/or per spinning position. 

The screen shows comparable data of both current and 

completed jobs. The data is updated with each doff and is, 

therefore, extremely precise. 

The POC increases efficiency – KPI (Key Performance 

Indicator) in a nutshell 

The latest addition to the POC gives users the comforting 

feeling of being informed at all times and in all places. Highlycondensed 

information on the production systems can be 

accessed on mobile devices using apps. 


integrated processes and efficient resources planning are 

becoming success factors. 

The POC connects the production hall with the management 

and creates the link between the ERP system and 

the control center. The various POC modules offer you the 

ideal tools to further increase the productivity and efficiency 

of your systems. The software is modular, allowing you to 

create a customized system from the POC modules that is 

tailored to your precise requirements and that can be expanded 

at any time. 

The POC simplifies the workflow – the “Recipe 

Management” module 

Recipes define what shall be produced. They include the 

complete list of all setpoints or parameters that are important 

for the product. During production planning, recipes are 

distributed to the production units.

Downstream process 

Texturing – high performance and reliability in 

harmony 

As long as there are chemical fibers, there will 

be the attempt to give smooth man-made fibers a 

natural fiber-like character. Texturing is a refinement 

step that transforms POY yarn into attractive 

and individual products. 

As early as 1954, Barmag developed the first false-twist 

texturing machine; today, Oerlikon Barmag is the market 

leader in this segment with over 1.5 million spindles supplied 

in more than 7,500 draw-texturing machines. 

There is a choice of a wide range of machines to meet 

every requirement. Whether manual or automatic machine, 

standard or multi-spindle configuration, each machine fulfils 

all the expectations which you have of Oerlikon Barmag in 

points of performance, quality, cost-effectiveness and innovation. 

The success of our customers is the focal point for Oerlikon 

Barmag’s development division. Process engineers and 

those responsible for components place the increase in yarn 

quality, production speed and flexibility at the centre of their 

activities. 


29

SUN – Service UNlimited 

Getting you to the top 

What are your expectations when you are deciding on new 

product ranges and equipment for your textile business? 

Do you really want to have several providers to manage the 

complex manufacturing processes you need to control? And 

can you risk facing the situation that after a few years your 

investment may be virtually worthless? 

We at Oerlikon Textile are convinced that you shouldn‘t 

accept any of these limitations. This is the reason why 

Oerlikon Textile has devised SUN – Service UNlimited – the 

new service initiative that our Customer Support offers with 

its brands Oerlikon Barmag, Oerlikon Neumag, Oerlikon 

Schlafhorst and Oerlikon Saurer to all its clients who require 

more than just service. SUN is a bundle of differentiated 

services that add real value to your Oerlikon Textile hardware 

and your daily business in a flexible way. 

Tailor made services 

Oerlikon Barmag Service offers you a broad range of products 

and services to achieve your objectives - faster return 

on investment, shorter downtimes and process support. 

Based in Remscheid, a pool of highly qualified employees 

equipped to react fast and efficiently to the most varied 

customer demands. From erection and start-up to process 

consulting – our team of experts is waiting to support you. 

Moreover, in line with „think globally, act locally“ our worldwide 

network of service stations will always reach you - 

everywhere. Local repair shops as well as on site workshops 

at your production plant are characteristic for our service 

philosophy. 

Our R&D center at Oerlikon Barmag’s headquarters in 

Remscheid is equipped with ten modules forming closed, 

self-sufficient units with a total of ten spinning plants on various 

levels. Here, customers can test their raw materials and 

products or develop new applications under optimum overall 

conditions. All modules can be independently operated in 

accordance with the respective process requirements. 

www.myoerlikon.com – access to success 

The myOerlikon customer portal is up to date at any time, 

24 hours a day throughout the whole year. The customer 

portal has a clearly arranged and uniform home page of all 

business units and their product lines. Our customers have 

online access to the latest documentation, tailor made for 

their machines. 


• Main Oerlikon Textile Service 

Network Stations plus more 

than 120 agencies worldwide 

The trouble-shooting manual permits a quicker and more 

efficient elimination of problems via direct links. The SECOS 

e-Commerce system, well-known worldwide, is completely 

integrated. The Engineering tool supports and accompanies 

the entire engineering process from the concept to the 

turn-key plant. Innovative ideas and new solutions are added 

continuously. Latest encryption technology guarantee the 

maximum data security at any time.


31

Oerlikon Barmag 

Zweigniederlassung der 

Oerlikon Textile GmbH & Co. KG 

Leverkuser Straße 65 

P.O. Box 11 02 40 

42862 Remscheid 

GERMANY 

Phone +49 21 91 67-0 

Fax +49 21 91 67-12 04 

www.oerlikontextile.com 

info.barmag@oerlikon.com 

Oerlikon Textile Inc. 

8801 South Boulevard 

P.O. Box 70 46 

Charlotte N.C. 28241 

U.S.A. 

Phone +1 704 910 42 68 

Fax +1 704 910 42 09 

info.charlotte@oerlikon.com 

The information supplied in this 

brochure is for guidance only. 

We reserve the right to modify it 

at any time. 

OBA 204 e / 6/2011 

Studio 45 / Koch 

Subject to changes 

Oerlikon Textile Far East Ltd. 

Room 2806 

China Resources Building 

26 Harbour Road, 28 / F. 

Wanchai, HONG KONG 

P.R.CHINA 

Phone +852 28 27 43 14 

Fax +852 28 27 52 50 

info.textile.hk@oerlikon.com 

Oerlikon Textile India Pvt. Ltd 

Empire Industries Complex 

414, Senapati Bapat Marg 

Lower Parel (West) 

Mumbay-400013 

INDIA 

Phone +91 22 6652 7900 

Fax +91 22 6652 7901 

management.bom@oerlikon.com

Solutions for POY manufacturing - Oerlikon Barmag - Oerlikon Textile

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