Professional Documents
Culture Documents
for DTY
manufacturing
As creative as the market
As creative as the market components for manufacturing company – with its approximately
Oerlikon Barmag, a division of manmade fibers, such as extruders, 1,600 employees – has a worldwide
Oerlikon Manmade Fibers GmbH winders, pumps and godets. As a presence in 120 countries as part of
& Co. KG with sites in Remscheid, future-oriented company, Oerlikon the Oerlikon Manmade Fibers network
Chemnitz, Wuxi and Suzhou (both Barmag’s research and of production, sales and distribution
People’s Republic of China), was development is driven by the idea and service organizations. At the
founded as Barmag AG in 1922. of energy efficiency and sustainable Oerlikon Barmag R&D Center – the
technologies. With the expansion largest of its kind in the world – within
The company is the world market of the product range to include the company’s headquarters in
leader for spinning systems and polycondensation systems and their Remscheid, highly-qualified engineers
equipment for manmade fibers, such key components, the company now and technicians develop innovative and
as polyester, nylon and polypropylene, caters to the entire process – from the technologically-leading products for
and texturing machines and – as a monomer all the way through to the tomorrow’s world.
service provider – offers engineering textured yarn.
solutions for the entire textile value Oerlikon Barmag machines and
added chain. At your service components rely on a large number of
The primary Oerlikon Barmag registered trademarks and international
High-tech from the market leader markets are Asia – China and India patents.
Its core competencies also include in particular – and the Middle East
the production of the associated and Europe. Correspondingly, the
Feed systems 6
Upstream processes 28
The automatic AFK and AFK2 and the single-section MPS automatic
texturing machine are past Oerlikon Barmag milestones, each generation
representing a quantum leap in texturing. They have now been
successfully superseded by the eAFK, which is already operating in
countries on five continents.
With the latest technology and modular machine structure, we provide our
customers with the right components for selecting the best suitable machine
cross sections for PES and PA according to the latest requirements.
Market oriented
For decades, manufacturing draw textured yarns was characterized by manual
processes. Changing manufacturing conditions in the main production areas have been
accompanied with a change in the process requirements and automatic machines have
once again become the focus. With our manual eFK and automatic eAFK draw texturing
machines, Oerlikon Barmag is catering – with future-oriented draw texturing machine
concepts – to the challenging creative and demanding markets of tomorrow through...
Energy saving Godet feed system, innovative drive systems and heater
designs allow potentially reduced energy consumption
Godet + ++ ++ + +
Draw and texturing zone
String-up solutions
In order to string-up the machine, proper placement of the yarn in the heater and cooling are of importance. Oerlikon
Barmag offers two systems to string-up yarn, which, as standard, are equipped with quick-release function swivel arms that
allow easy push in & out of twist stop rollers and yarn guides.
Pneumatic
The pneumatic string-up solution uses compressed air to move the function swivel arm into the top position by deploying
a magnetic sledge, which also secures the positioning when in place. Easy operation by push buttons on each string-up
position makes the pneumatic string-up as operator-friendly and process secure as possible.
Manual
The manual string-up solution makes use of a pulley mechanism using a shaft to allow operators easy and correct
placement of the function swivel arm into the top position. The shaft is secured against movement with a brake. Each
position is equipped with one string-up mechanism.
Texturing zone
Technological limits depending on yarn product are: Oerlikon Barmag HTM heaters are open-close heaters for
easier operation and maintenance, equipped with manually
• Surging closing doors. They are available in various lengths suitable
• Yarn tension for processing different ranges of products. Depending
• Desired yarn quality on the product portfolio customers can optimize their
production with the right selection and combination of
heater and cooling component. The correct selection of
Physical limits depending on yarn product are: these components can influence
HTI
Depending on product titer and number of filaments, the The HTI high-temperature heater makes it possible to
selection of heating component in combination with cooling achieve high speeds coupled with excellent yarn qualities
component can either improve the yarn quality or optimize due to stable yarn path and uniform heat transfer. The
the process speed – or both. An important side effect of this 1-m-long heater comprises two heating zones that –
effort is the potential energy saving due to the selection of equipped with special exchangeable inserts developed
the heater Apart from optimizing production, energy saving and patented by Oerlikon Barmag – enable fast and simple
based on heater selection reduces total manufacturing costs. replacement during standard maintenance work.
In today’s demanding market, environmental optimization of
production can be the difference between profit and loss. This increases overall machine efficiency by minimizing idle
machine time resulting from maintenance and cleaning. The
Oerlikon Barmag offers a wide range of upper structure inserts are cleaned outside the machine, hence eliminating
combinations that help our customers to achieve the highest the customary problems associated with heater cleaning.
process speeds for high-quality products with the lowest
possible energy consumption. Inserts are available for both heating zones, either with
pinches or as full contact inserts. Different inserts can be
Primary heater1 combined for optimization of the process, catering to the
special needs of highly critical products.
HTM
HTM contact heaters have been successfully used in Due to its design, the Oerlikon Barmag HTI heater has
Oerlikon Barmag machines for over 30 years now and are – significantly lower energy consumption in comparison to
even today – state-of-the-art technology, particularly for its HTM cousin. This – combined with significant potential
multifilaments and microfilaments. Anti-wear nitrated process speed increase – makes the HTI heater a
surfaces, deep V profile and special pinches for preventing worthwhile alternative investment consideration.
yarn heat-outs result in high yarn cleanness, extremely even
crimping and excellent dye uptake for the textured yarn.
1
Vapour-heated
Depending on product and process, the right combination of heating and cooling components is important for optimized
yarn production – crucial in today’s demanding markets. Oerlikon Barmag offers a variety of cooling components that are
designed to work in harmony with our heater products.
Plates
Cooling plates have been developed by Oerlikon Barmag in line with the heaters. In each case, they offer the same process
relevant features such as anti-wear nitrated surfaces, deep V profile and special pinches for preventing yarn cool-outs.
Cooling plates are available in various lengths to allow optimum heat transfer, depending on the product.
Cooling Titer range Preferred Yarn Usually in Typically used for Typical application
length den operational treatment combination polymer/den
range with heater
0.70 m 20 – 150 20 – 100 ++ 1.5 m HTM* PA, PP, PTT Fine yarn, micro- and
2.0 m HTM* 20 – 70 multifilament
0.85 m 20 – 200 20 – 150 + 1.5 m HTM* PA, PP, PTT Fine yarn, micro- and
2.0 m HTM* 20 – 100 multifilament
1.10 m 30 – 300 30 – 200 o 2.0 m HTM* PET, PA, PP, PTT Average commodities
30 – 200
1.75 m 30 – 300 30 – 300 - 2.0 m HTM* PET, PA, PP, PTT Fine yarn
1.0 m HTI* 30 – 300 commodities
2.10 m 100 – 600 150 – 450 -- 2.5 m HTM* PET, PA, PP, PTT Coarse
Cooling Titer range Preferred Yarn treatment Usually in Typically used Typical
length den operational combination for polymer/ application
range with heater den
0.80 m 20 – 300 20 – 200 ++ 1.5 m DT* PET, PA, PP, Fine yarn, micro- and
1.0 m HTI* PTT multifilament
20 – 200 High speed
Low friction
1.20 m 30 – 600 70 – 300 O 1.0 m HTI* PET, PA, PP, Fine yarn, micro- and
PTT multifilament
70 – 300 Commodities,
High speed
Apart from the early days of texturing machinery, Oerlikon Barmag has always focused on friction disc units as
the most advantageous and flexible form of twist insertion. Using different types of friction working discs as
well as specially developed inlet and outlet discs, the friction units can be adapted to any kind of product for
optimal production.
In line with the modular machine design concept, Oerlikon Barmag offers single-drive and belt-driven friction aggregates in
fixed center or open close design for all applications. The automatic eAFK is, as standard, equipped with single-drive
aggregates, whereas either centrally belt-driven or single-drive aggregates can be selected for the manual eFK. In single-
drive execution, both friction aggregates share the same single-drive housing, are interchangeable and as such provide
customers with additional flexibility, optimizing the process.
• High flexibility for a wide range of products – from fine 20 denier up to coarse 450 denier
• Designed for a maximum stacking of 10 discs with 9-mm thickness or 13 discs with 6-mm thickness
• Elastic and muffled high-speed bearings for extra-low vibration at high speeds (up to 22,000 rpm)
• Low noise level
• Low variation of disc speed
• Lower energy consumption
• No displacement of texturing unit and entrance guide at S/Z switching
• Easy reversal of twist direction
• Easy removal of friction unit for maintenance purposes
With rising quality requirements, the demand for online quality monitoring systems is also increasing. The
target is not only monitoring the draw-texturing process, but also improving the overall process and increasing
machine efficiency. With Oerlikon Barmag’s online quality monitoring, products that do not meet set quality
standards are easily identified, withdrawn from the production process and replaced by yarn that meets the
quality requirements. Hence, machine efficiency is increased – valuable machine time is not used to process
yarn that does not meet the required standards!
Intermingling of yarn – and here especially the number and regularity of the intermingling knots – are one
of the prerequisites for high-end downstream operation. Oerlikon Barmag, in close cooperation with world
renowned brands for intermingling jets, offers a wide range of intermingling possibilities throughout the
process for all texturing machines. Intermingling is an option that – depending on downstream requirement –
has to be discussed.
Pre-intermingling It comprises two feed systems (G2 and the additional G2x)
While processing fine denier and especially highly challenging that allow stable and controlled yarn processing within a
microfiber with high number of filaments, pre-intermingling defined area. The integrated intermingling piping, equipped
can be an attractive solution for improving the quality of with straight couplings, offers easy handling and operation
the final yarn, overcoming manufacturing problems and of the respective jets.
increasing overall machine performance.
Detorque
Furthermore special products manufactured with special In the event that customers wish to produce close to zero
intermingling jets can create competitive advantages. torque yarn without the need to ply yarns, Oerlikon Barmag
Oerlikon Barmag texturing machines offer the possibility offers a detorque intermingling system for its machines.
for implementing the intermingling piping required for Located between the secondary heater and the third feed
pre-intermingling at the first feed. unit the intermingling piping can be equipped with special
jets that create a yarn that is not completely without torque,
Intermingling but with minimal torque. Detorque works only with PET
Regular and high-quality intermingling is crucial to success and requires a set heater. It is an alternative to plying yarns,
especially for downstream weaving applications, particularly which reduces the take-up capacity of the respective DTY
for warp yarns. To achieve the best-possible intermingling, machine by half (for 2-ply), in the event that the yarn is plied
the Oerlikon Barmag texturing machines include the so- on conventional rather than multispindle machines.
called intermingling zone upstream to the secondary heater.
Oiling solutions
The application of oil is important for smooth operation throughout most processes within the textile
process chain. Depending on the downstream setup, a certain amount of oil may be required for higher
efficiency and fewer disruptions. Oil applied in one step of process is usually consumed or eliminated
during the following process step, only again to be applied if required in the next step. For some products
and downstream processes, oil is particularly undesirable, as in the case of dyeing applications, for
instance. Respectively, a certain technical flexibility must be considered. The location of the oiling device,
the form of oil application and the polymer type can influence the process and are therefore important for
efficient operation and high-quality production. Oerlikon Barmag texturing machines provide a practical
and proven solution for each requirement.
Oiling solutions for manual machines - eFK so-called HE yarns (high elasticity) with either PA or PP
being typical polymers. As there is no secondary heater and
Central oiling – upper or lower deck oiling no third feed unit, the oiling is located on top of the take-up
The typical basic oiling solution depends on the availability after feed unit 2 or 2x.
of a secondary heater in the machine configuration. If the
end product of the texturing process is a set yarn, the oiling For special applications both upper and the lower oiling may
device has to be located between the third feed unit and the be required in one machine. This is easily accomplished with
take-up. This is usually in the lowest position of the eFK. Set the flexibility of the eFK. Central oiling application rollers are,
yarns are typically PET yarns. as standard, equipped with toothed rollers applying oil to the
yarn running over the roller teeth. For special applications
For products that – due to their physical properties - do that require more accurate oil application, Oerlikon Barmag
not require heat setting or – due to the process – it is not offers application rollers with a V groove along the yarn path
desired, a machine cross section without a secondary with vertical grooves to allow easy removal of possible yarn
heater is usually selected. These machines produce so wraps.
Similar to the eFK manual machine, Oerlikon Barmag offers The eAFK with single deck oiling provides the most even
a single deck and central oiling solution for the eAFK. process conditions from package to package as well as
from deck to deck, thus improving the overall production
Central oiling quality.
The central oiling solution derived from the previous
generation AFK2 machines is located after the W3 shaft
below the take-up. It comprises, as standard, toothed rollers
or alternatively grooved rollers for the oil application and
fulfils all basic oil application requirements for PET or PP
products. Central oiling is not recommended for processing
of PA yarn.
With the further development of downstream processes, the requirements for the DTY package constantly
increases. Best possible package formation and the related unwinding performance are key for efficient
manufacturing with up-to-date technology. Oerlikon Barmag offers two take-up solutions. The basic, proven
and reliable camshaft take-up for quality package formation as well as the high-end solution for best-
possible package formation including density control - ATT (Advanced Take-up Technology). Both systems
come with our next generation bobbin lever, are optionally available for our manual eFK and can be selected
by customers depending on the requirement. Our automatic eAFK is, as standard, equipped with ATT in
conjunction with an automatic doffing unit.
ATT – Advanced Take-up Technology • Actively control the decrease in winding tension
The quantum leap in package building technology comes • Gradually lower the decrease in winding tension even
with a single-position drive solution, fewer mechanical down to a constant winding tension
components and computer-control of every single stroke • Higher package weight
throughout the package formation, providing significant • Even package density
benefits for the manufacturer and for the product itself. • Prevention of yarn damage by reduced initial winding
Furthermore, ATT allows for special solutions, such as tension
unique flexibility in package geometry or quality indicating • Unique features for winding dye packages
marking of packages, which have – until now – been
impossible using mechanical take-up units. A further feature is the choice of various take-up programs
with an individual calculation of each stroke for even yarn
distribution over the entire width of the package as well as
uniform pressure distribution on the tube.
IAD – Individual Automatic Doffer Two parking positions, in conjunction with one further full
The further improved individual automatic doffer being used package in production, allow unattended operation for
as a standard in conjunction with our eAFK is the culmination longer periods of time, depending on yarn titer.
of Oerlikon Barmag’s experience in automatic doffing.
Oerlikon Barmag’s take-up solutions with CAM or ATT provide
Reliable doffing performance to ensure the highest-possible
machine efficiency is the result of a sturdy take-up section in • Up to 384 positions
low-vibration design combined with Oerlikon Barmag’s CPC • Bobbin levers: CPC system for automatic machines;
(contact pressure control) bobbin lever system. Adjustable SPC system for manual machines
for different package densities, it allows - in conjunction • Winding of taper-ended packages with nominal taper
with the Oerlikon Barmag TUP (Take-up Processor) - the angles of 65° - 90°
best-possible package formation with excellent take-off • Max. package diameter - 250 mm
performance. • Traverse stroke length: CAM traverse stroke length -
250 mm
During the doffing procedure, waste injector systems ATT traverse stroke length - 250 mm (max. 273 mm)
transport waste yarn into easily accessible bins located on • Max. double strokes per minute CAM: ≤600ATT: ≤800
the creel side of the machine. • Traverse drive with ribbon breaking unit as well as with
scattering system variable for the highest process speeds
Apart from the considerably reduced noise level due to
use of the ATT system in the take-up section, the basic
functionality of the IAD is the production of packages of
uniformly-metered length.
Dynamic markets require special solutions for special products. To excel in these conditions, flexibility of
manufacture as well as machinery is a must. Special yarns are partially fashion-influenced or for special
applications. With our modular design, the implementation of supplementary components for special
processes in line with the machine’s feed concepts are easily accomplished.
Elasthane device Hot pins can only be added to the eFK machine and require
Blending of elasthane with PET or PA yarns targeting one additional feed unit for operation.
improved comfort in the end product is becoming a
standard application. Usually a two step process, the Additional feed shafts
elasthane covering device of the eFK or eAFK allows In addition to the implementation of elasthane feed or hot
production of yarn and covering in one step, hugely pins, special effects can be achieved with additional feed
improving the economy of the process. By covering yarns units in the yarn path. Up to three feed units – depending on
with elasthane during the texturing process, even better the other components - can be added in the feed section
stability of the final yarn product can be achieved-beneficial of our manual eFK. With these feed units, the following
for further downstream. processes are possible:
Hot pins
For production of thick and thin, the eFK can be equipped All possible options of our machinery target either reduced
with hot pins. To achieve the thick and thin effect, yarn is manufacturing costs or higher profit due to greater flexibility
drawn around a heated pin in irregular movements.This heat and variety in product range or by integrating processes.
treatment prior to the draw texturing process causes thick
and thin places that appear in the final fabric depending on
the downstream process either as a cloudy or stripe effect.
Process
Products Dpf Advantage
Cross
sections
220-300
high mid
150-220
very fine
flexibility
0.2-0.5
1.0-5.0
special
75-150
0.5-1.0
coarse
energy
quality
saving
speed
20-50
50-75
mid
fine
Standard • • • • • • •
Coolflex • • • • • • • •
Multispindle • • • • • • • • •
HTI • • • • • • • • •
HTI coolflex
1.0/1.2
• • • • • • • • • • • •
HTI coolflex
1.0/0.8
• • • • • • • • • •
PA standard • • • • • •
PA coolflex • • • • • • •
This cross section as single heater machine in conjunction with single deck
oiling is the preferred processing solution for mid denier polyamide yarns.
– Reduced friction
– Elimination of contact points
– Implementation of heater and cooling with greater operational window
– Straight yarn path
Suitable for microfilament yarns and fine to mid denier, while allowing a
greater operational window for higher denier.
Versatility for efficient and high-quality production at highest process speeds is achieved by
Suitable for fine to mid and coarse denier in the 30 – 300 den range with an optimized operational
window.
POC – Plant Operation Center – is the all-embracing ideal tools to further increase the productivity and efficiency
workflow management system from Oerlikon of your systems. The software is modular, allowing you to
Manmade Fibers. It is designed to detect and optimize create a customized system from the POC modules that
the production processes within a production stage, is tailored to your precise requirements and that can be
e.g. spinning, texturing or overall production stages – expanded at any time.
starting with the raw material up to the end product.
Furthermore, the POC archives all relevant data for several
Today, companies are confronted with challenges on all months and, optionally, up to six months. This allows the
fronts: market requirements are becoming increasingly customer a comprehensive overview of the development of
difficult to plan, pressure on margins is growing and the processes and the procedures within its production facilities
production environments of dynamic companies are at all times. A comprehensive review of the manufactured
becoming ever more complex. Within companies, data product qualities is very important, particularly when the
transparency, integrated processes and efficient resources objective is continual product optimization. Here, the
planning are becoming success factors. available long-term data are an invaluable tool for yarn
manufacturers.
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
The POC creates transparency - the “Job Reports” The POC Shift Report gives information about the shift
module related production results of a production plant. Yarn
The POC Job Reports gives us an up-to-date and exact producers may obtain the evaluation of typical shift data.
summary of all manufacturing jobs in the line. The summary The shift data will be presented either as trend diagram for
includes information on both complete manufacturing jobs several shifts or may be broken down to machine related
and those still running. These informations are refreshed views per shift.
with each doff and for each package, respectively.
Consequently, they are very precise at any time. The The POC Fault Report delivers information about all yarn
corresponding views show the current information per faults identified by the online quality control system. The
job, per machine and per position. As an option the POC user obtains an evaluation of the different yarn fault types.
interface to ERP can be used to forward the data of already The yarn fault evaluation can be broken down from a
finished manufacturing jobs to a customer ERP system. machine-related representation to a position-related view.
Thus, the POC Fault Report is designed to help the user to
The POC retains the overview - the “Reports and quickly identify machines or positions with the maximum
Statistics” module count of yarn faults. This information helps to increase
The ‘Reports and Statistics’ module offers various reports production quality and efficiency. The POC Fault Graphs
with various views and filters – production report, shift supplies access to all fault graphs of doffed packages within
report, fault report, etc. – which enable yarn manufacturers a texturing plant.
to make their process and production procedures
transparent and to adapt and adjust the production results The user receives a tool to evaluate the specific reason of a
in good time. recorded tension fault. Herewith the yarn fault evaluation is
not only presented as numerical values of predefined fault
The POC Production Report provides information about categories but also as a detailed yarn tension graph with
the accumulated production results of a production plant. maximum fault information.
Users may obtain the evaluation of typical production data,
such as numbers of packages of the different quality views.
categories or the full / short package ratio. The production
data will be presented either accumulated on a lot related
basis or may be broken down to machine or position related
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 Manmade Fibers’s strong global network form a solid basis and the perfect
prerequisites for Oerlikon Barmag as a solutions provider.
Plant engineering
The growing demand for engineering services - particularly from various newcomers to the fiber/
filament manufacturing and processing sector - has resulted in the setting up of an Oerlikon Barmag-
internal engineering division. 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.
With Oerlikon Barmag polycondensation, the yarn producer will reduce dependencies and will be able
to determine the characteristics of the raw material. With more than 80 years of experience, Oerlikon
Barmag knows the requirements of filament spinners and converts them into process-optimized
systems concepts.
POY spinning
With more than 30,000 spinning units supplied in the last 10 years, POY systems are the most
successful Oerlikon Barmag products. Several decades of continuous research and development
today allow all customers to produce the most varied POY filaments efficiently and cost effectively.
Oerlikon Barmag POY systems supply the best package quality and thus guarantee the highest pull-off
speeds and an excellent dyeability of standard titers, microfilaments and high-count yarns.
For this we offer you the performance of a technology leader with a unique global
service network, along with highly qualified service and engineering experts. We
will advise and support you in all phases of your business along the entire value
creation chain of fiber production:
- with start-up services for the installation or relocation of your systems,
- with technical support round the clock,
- with modern services for maintenance and repair, performance
enhancement and staff training, and
- with modernisation and upgrades from the manmade fiber specialist.
Whatever you need, you can select services tailored to those requirements from a
service portfolio that is unique in the industry.