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POY Spinning with WINGS Sustainable Solutions

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POY Spinning with WINGS Sustainable Solutions POY spinning with WINGS Sustainable solutions From Melt to Yarn Your benefits From Melt to Yarn .................................................. 4 POY production with WINGS .................................. 6 Key benefits High yarn quality ................................................. 8 Savings in Opex ................................................ 10 High efficiency ................................................. 12 Easy handling ................................................... 14 Large operation window .................................. 16 Plant Operation Center (POC) ............................... 20 Partnering for Performance .................................. 22 Downstream process ............................................ 24 Our arguments ...................................................... 26 POY spinning with WINGS – Oerlikon Barmag 3 From Melt to Yarn Solutions along the textile value chain Place your business ideas in professional hands! Consulting, engineering, plant construction Melt Preparation and high-tech machinery – the whole package from a single source. Many years of experience in textile machine construction and our strong global network form a solid basis Continuous Polycondensation Extrusion and the perfect prerequisites for us as your solutions provider. Define your yarn properties from the very outset Extensive experience and engineering and management com- From chemicals to manmade fibers, from melt to yarn, from petencies help us deliver even complex projects and process- Pumps polycondensation to texturing – we have your value-added es on time. You can rely on that! chain under control. And you increase your profits. Because an optimized manufacturing process encompassing all pro- Spinning duction steps provides you with the greatest-possible influ- ence on the quality of your end-product. And your production costs. Add to this the fact that our brand strength will make Quenching financing your project a profitable investment. EvoQuench Crossflow Quenching POC Take-up Customer Services WINGS WINGS XS or ACW Texturing AFK eAFK 4 POY spinning with WINGS – Oerlikon Barmag POY spinning with WINGS – Oerlikon Barmag 5 What is POY production with the WINGS concept? The POY process with WINGS is the world’s most efficient solution for manufacturing pre- oriented yarn (POY). This unique process unites state-of-the-art compact winding technology with innovative spinning concepts. To ensure you can compete within the global market. The idea The benefits Developed with the aim of increasing the productivity and Your success is very important to us. For this reason, we efficiency of POY systems, the WINGS concept bears its solu- always maintain a focus on the benefits to you when developing tion in its very name: Winding INtegrated Godet Solution – in our products. Profit from short, WINGS. That was the beginning of a revolutionary idea High yarn quality for integrating the take-up unit and the draw unit into a single Savings in Opex system. And this winding concept remains absolutely unique: High efficiency meanwhile, it has established itself as the global standard in POY production and convinces in conjunction with smart core components in the spinning system with Reliable technology Particularly gentle yarn path Consistently good yarn quality Outstanding package build Ergonomic component layout Compact design e-save provides you with a competitive edge With e-save, Oerlikon Manmade Fibers introduced a label for particularly energy-efficient sys- tems, machines and components back in 2004. Over the past years, e-save has established itself as the trademark of a comprehensive efficiency program. This underlines the preeminent role of Oerlikon Manmade Fibers when it comes to commercial success and sustainability. POY spinning systems with WINGS are setting standards. Compared to conventional concepts, this solution convinces in terms of Energy: with up to 25% lower energy consumption Economics: with up to 20% fewer operating staff, more than 50% shorter string-up times and up to 35% less space required Environment: with up to 30% less waste Ergonomics: due to the reduction in system levels by one and the resulting simpler system operation. 6 POY spinning with WINGS – Oerlikon Barmag POY spinning with WINGS – Oerlikon Barmag 7 High yarn quality Savings in Opex High efficiency Easy handling Extensive process window Producing premium yarns with EvoQuench, WINGS and co. Would you like to manufacture premium yarns? We will help you – with our high-perfor- mance spinning system components; from the extruder and the spinning pump, the spin beam and the spin packs all the way through to the quenching system. Because the quality of the yarn is determined by the spinning system. EvoQuench for fine micro-yarns WINGS gently places the yarn on the package Within the complex spinning process, the quenching unit en- The quality yarn has been spun, now it has to be wound. To sures even cooling of the liquid filaments at the outlet of the ensure it is subjected to the correct treatment in this stage, spin pack. And therefore guarantees excellent yarn evenness. we place the yarn in the hands of WINGS. With its particularly Our patented EvoQuench radial quenching unit covers a further gentle yarn path, WINGS guarantees that your yarn maintains production step: everything from 0.3 to 3.1 titers is possible for the high quality it had upon exiting the spinning system. For standard yarns all the way through to fine microfilaments. And this, we have minimized the angle of deflection to 7 degrees you can rely on our cross-flow quenching system for coarse in total, which has a positive impact on the yarn evenness, the and standard titers. yarn tension, the CV% values and consequently the dyeability. Needless to say, the package build is also perfect and ensures excellent further processing properties for the downstream processes. Here, we paid special attention to the outstanding take-off behavior of our packages to cater to the high produc- tion speeds of our texturing machines. The high full package rate within the texturing process is testament to the quality of the package build with the WINGS winding concept 8 POY spinning with WINGS – Oerlikon Barmag Key benefits POY spinning with WINGS – Oerlikon Barmag 9 High yarn quality Savings in Opex High efficiency Easy handling Extensive process window Cost-efficient manufacturing – also in the premium segment Competition within the yarn markets is becoming more intense. The consequence: constantly rising pressure on costs. The solution: optimized production processes, efficient systems, sustainable technologies. All these are provided by our POY technology with WINGS. Less is more Reduced air consumption: EvoQuench POY processes with EvoQuench quenching systems and Cooling air is the main energy consumer when it comes to WINGS take-up concepts are more profitable than conven- quenching. Our solution is the EvoQuench: this radial quench- tional POY processes. Why is this? Less is more: Up to 20% ing concept from Oerlikon Barmag consumes up to 80% less fewer operating staff as a result of the reduction in system cooling air compared to cross-flow quenching. Convinced? height by one level, the optimized and automated string-up process. Up to 25% lower energy consumption due to low- Optimized take-up: WINGS Savings in OPEX er air and air-conditioning requirements and energy-efficient And WINGS also reveals its frugal side when it comes to en- WINGS PET POY production costs components in the spinning system and the take-up unit. Up ergy: the considerably reduced string-up times alone result in to 30% less waste as a result of 50% shorter string-up times. the take-up concept requiring substantially less compressed 100 Up to 35% less space required as a result of the compact air – hence contributing to the energy savings. Further factors construction of the WINGS take-up concept. include the special intermingling concept and the energy-effi- Conventional POY 15 - 20 % 90 savings 25 % cient drives. 30 % savings 35 % Reduced heat loss: SP8x 100% savings 80 savings Heat is a very considerable factor in polymer spinning sys- High machine availability tems. Generally, the melt is conveyed from the polycondensa- High machine availability is relevant for a high full package rate. 70 tion unit to the spinning system at temperatures of between Which in turn increases your profits when you market your 80-85% 284 and 288 degrees Celsius. This harbors potential for en- POY. Or ensures smooth further processing if you carry out 75% 60 ergy optimization: in our SP8x spinning head series, we have texturing in-house. This is guaranteed by the robust, reliable 70% considerably reduced the heat-radiating surface, while simul- and high-performance control and drive components supplied 65% 50 taneously substantially improving the insulation compared to by Siemens, our development partner for many years now. the predecessor models. The result: more than 40% less heat 40 loss. What does this mean in concrete figures? For a system with 36 positions, this generates an energy saving of around 30 200,000 kWh per year. 20 10 % Staff Energy Waste Space 10 POY spinning with WINGS – Oerlikon Barmag Key benefits Key benefits POY spinning with WINGS – Oerlikon Barmag 11 High yarn quality Savings in Opex High efficiency Easy handling Extensive process window Less waste – greater profit Efficiency is the most important characteristic of WINGS: It can be completely operated from floor level. All elements
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