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 systems, 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-performance 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 production 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.

% 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 are laid out at eye level. Consequently, this 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. 50% faster string-up – which translates into 30% less waste.

Partially-automated string-up process minimizes Fewer operators required the operating error rate WINGS moves at eye level. What does this mean? One level The partially-automated string-up process supports the natu- fewer than conventional POY manufacturing solutions, for ral work routine of the operator. And hence optimizes the example. For your operating staff, this means solo string- interaction between man and machine. With this, the take- up. What is the benefit to you? You require fewer members up system offers the world’s fastest and simplest string-up. of operating staff for the successful operation of your POY system. Which has a positive impact on the cost-efficiency of your yarn production.

Due to easy-to-operate components and our single process control system, the plant can be operated by only 3-5 operators.

POY spinning with WINGS (picture right) has one operating level fewer than conventional POY spinning solutions (picture left). This saves operating staff.

12 POY spinning with WINGS – Oerlikon Barmag Key benefits High yarn quality Savings in Opex High efficiency Easy handling Extensive process window

Less and easy maintenance saves you time

There is no such thing as a maintenance-free POY system. However, we supply systems requiring minimum maintenance. And it is once again the WINGS take-up concept that gives you an edge.

As a plug-and-produce unit, the complete take-up unit can be removed from the system for maintenance in just a few minutes. Each one individually and independent of the others. This minimizes the downtimes for the respective position or even the entire system.

Better start-up performance WINGS simplifies and shortens the installation of the system. The entire WINGS take-up concept is delivered from our technology hub in Germany as a completely pre-installed and tested unit. This makes assembly and commissioning of the POY system of today child’s play. All that is required onsite is the connection of the power and compressed air supplies. With this, we have dramatically reduced the assembly and commissioning times. The benefit to you: you can start manufacturing POY up to two weeks sooner.

14 POY spinning with WINGS – Oerlikon Barmag Key benefits High yarn quality Savings in Opex High efficiency Easy handling Extensive process window

Unlimited possibilities – product diversity for your premium yarns

Our POY technology offers you a comprehensive process window – without compromises in terms of the yarn quality.

Our spinning and quenching concepts in conjunction with WINGS enable all standard yarn products.

WINGS concept covers virtually all processes WINGS POY 1800/12 The POY spinning system is a family matter. The WINGS family has increased in size over the years and meanwhile covers virtually all processes. Standard or micro-yarns, polyester or polyamide, POY or HOY, 10-, 12- or even 24-end – whatever you wish to manufacture, we have the right WINGS for the job.

As a platform-based component, WINGS guarantees state-of- the-art technology here.

Variety of processes with WINGS Process/threads 10 12 20 24

PET POY X X X X PA6 POY X X PA6.6 POY X PA6 HOY X X

Modernizations with WINGS XS And you do not have to do without the WINGS take-up technology when modernizing existing spinning systems either. With our special 8-end RetroFit design, you can also make older POY systems competitive again. WINGS POY 1600/8 XS For more information, please contact our service department: [email protected].

WINGS HOY 1500/12

16 POY spinning with WINGS – Oerlikon Barmag Key benefits Key benefits POY spinning with WINGS – Oerlikon Barmag 17 High yarn quality Savings in Opex High efficiency Easy handling Extensive process window

Microfiber yarns The finer the yarn, the better it feels. Hardly surprising that virtually half of all yarns manufactured are now made from microfibers. We support you with the right spinning system and the right take-up unit. Regardless of whether polyester or polyamide.

Spun-dyed yarns Spun-dyed yarns are in demand above all when the end-product needs to be colorfast and lightfast. Spun-dyed yarns are standard particularly in the demanding automobile industry. If microfilament yarns are required, our EvoQuench radial quenching system – especially tailored to the requirements of the spinning process for spun-dyed yarns – makes its mark. For manufacturing commodity yarns, we recommend using our cross-flow quenching system.

Bicomponent yarns Bicomponent yarns have many benefits: here, even finer titers per filament (dpf) are possible than in the case of microfiber yarns, for example. The application possibilities are virtually unlimited. Here, the most varied cross-sections are available – More on Oerlikon Bamag from orange type, side-by-side all the way through to islands- microfiber, spun-dyed and bicomponent yarns in-the-sea. And what about manufacturing? Let’s talk about it! [email protected]

Or contact us: [email protected]

18 POY spinning with WINGS – Oerlikon Barmag Key benefits Plant Operation Center (POC) Industry 4.0 optimizes processes

The Plant Operation Center (POC) has for many years been an established process and production management system for the Oerlikon Manmade Fibers machines and systems deployed to manufacture textile yarns. For this, we adapt the Plant Operation Center precisely to the respective requirements of each customer.

This is made possible by the modular character and the scal- Networked production ability of the system. And retrofitting additional modules is very Particularly interesting for the efficient and transparent produc- simple. Numerous convinced customers speak for themselves. tion process: in a network of Plant Operation Centers, informa- But the Plant Operation Center is capable of far more: the entire tion can be securely exchanged between the various manufac- installed process chain can be connected. With this, the Plant turing sites in a controlled manner. Operation Center networks the entire production solution and the corresponding work-flow.

Quality guarantee What are the benefits of such a process and production management system? All process values relevant to the quality of your product are continually recorded and form the basis of online quality monitoring. The criteria and rules of quality assessment are defined by you. This applies both to online quality assessment (pre-doffing) and offline quality assessment (post-doffing).

Clear overview Your manufacturing orders are set-up in the Plant Operation Center and continually updated and displayed. You can track each order and each product at all times. This is valid both for currently running and already completed manufacturing orders. And the Plant Operation Center is also becoming mobile: in addition to the desktop- and web-based workstations available since its launch, mobile devices are increasingly supported. To this end, you have the current key performance indicators (KPIs) available to you on your smart phone at all times and wherever you happen to be. And critical situations and condi- tions and urgent tasks are also relayed to your operating staff using mobile devices. Which in turn helps improve ‘operational performance’.

20 POY spinning with WINGS – Oerlikon Barmag POY spinning with WINGS – Oerlikon Barmag 21 Partnering for Performance Maintain your success!

Progress is steaming ahead within the textile machine and systems construction sector, with production processes continually improving. However, production processes are also becoming increasingly complex and require reliable steering and monitoring to prevent expensive machine downtimes.

Those dispensing with optimally-tuned service are taking a Think globally, act locally huge risk: investments can quickly become absolutely worth- Under the Partnering for Performance umbrella, our Oerlikon less if the technology or the service fails to be future-proof or Manmade Fibers Service offers a plethora of the most diverse performance-compliant. products and services to ensure that you reliably achieve your goals: faster return-on-investment (ROI), shorter downtimes Collaborating with you, Oerlikon Manmade Fibers’ mission and optimized production processes. We will swiftly and ef- statement is to ensure that your production processes run ficiently implement your requirements – at any time and any- smoothly. For this reason, our motto and ambition is: Part- where, a pledge that is backed up by highly-qualified employ- nering for Performance. This stands for a service initiative ees at our headquarters in Germany along with our network of benefiting all customers who expect more than just service over 20 worldwide service stations. alone. The Partnering for Performance offerings ensure that your systems remain state-of-the-art: profitable and ready for operation, hence ensuring you make a sound decision – for future-proof investment, for technological leadership and for production reliability in your day-to-day operations.

Find out more on Oerlikon Barmag Customer Services

Or contact us: [email protected]

22 POY spinning with WINGS – Oerlikon Barmag POY spinning with WINGS – Oerlikon BarmagKey Benefits23 Downstream process We know how ...

Your POY needs to be textured to turn the spun semi-finished product into a yarn that can be processed into textiles.

And we will support you here: we have also been experts in this process step since the 1950s.

DTY – are you ready to evolve? Manual or automatic, single or multiple – choosing the right texturing solution for customized yarn production depends on many factors. With our eFK manual texturing machine and its automatic counterpart, the eAFK, we have the answer to all your needs. Our texturing machines look forward to receiv- ing perfectly-wound WINGS POY packages with outstanding take-off performance. And produce first-class DTY with them. As we know what the requirements are for POY to ensure perfect DTY. This is what you get when you choose a solutions provider who feels at home in the entire textile value added chain!

Needless to say, we also look beyond the horizon: our exper- tise in weaving and warp-knitting processes helps you offer your customers perfect yarn. And we also focus on yarn and textile trends. Speak to us! [email protected].