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Solutions

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

2 DTY – Oerlikon Barmag


Draw texturing solutions 4

Feed systems 6

Draw and texturing zone 7



Take-up zone 16
Oiling solutions 16
Take-up solutions 18

Options / cross sections 20


Standard
Coolflex
Multispindle
HTI
HTI coolflex 1.0/1.2 active
HTI coolflex 1.0/0.8 active

Plant Operation Center 26

Upstream processes 28

Partnering for Performance 30

DTY – Oerlikon Barmag 3


Draw texturing solutions
from the market leader.
As good as it gets.
Having delivered more than 9,000 manual and 1,000 automatic texturing
machines, Oerlikon Barmag is the world’s leading and most sought after
texturing machine manufacturer for all kinds of polymers. While the
manual FK6 was the backbone of the industry, its successor eFK – with
tailor-made flexibility as a result of its evolutionary modular design – is the
best market entry of the past decade.

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.

Reliability, efficiency, userfriendliness and the most economical


production of high-quality yarns are the basic criteria Oerlikon Barmag
texturing machines must fulfill.

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...

Economy Reduced manufacturing costs with superlative doffing


efficiency, less wear and spare parts and potentially higher
process speeds through innovative cross sections

Efficiency Improved machine efficiency with less downtime through


reliable doff operation, automation interface and simplified
maintenance and operation

Excellence Superlative package formation with future-oriented ATT

Ergonomics Operator-friendly machine handling

Energy saving Godet feed system, innovative drive systems and heater
designs allow potentially reduced energy consumption

Enhancement Improved yarn quality and process stability for a wide


range of products and polymers (PET - incl. PTT -, PA /
PP / PLA), especially for demanding products

Evolution Closely listening to the market, our machines improve and


evolve with rising requirements

4 DTY – Oerlikon Barmag


Feed systems

Godet feed unit Shaft feed unit


The single-drive godet feed unit as used in G1, G2 and The centrally-driven shaft feed systems fulfill all the basic
G2x has – as a principle – been derived from POY spinning. requirements for processing even delicate products from all
It was introduced by Oerlikon Barmag in DTY machines in kind of polymers. The W3 shaft is standard for both
2003. Optimized for the DTY process, it quickly convinced manual and automatic machines, whereas shafts can be
in those areas in which superlative requirements for yarn selected as an alternative to godets only for the eFK
processing were key. Stress-free yarn transport offers with all other feeds. Yarn feed takes place in conjunction
advantages for both sides of the product spectrum. with nip rollers or – if required – aprons. For easy handling
and maintenance, nip rollers are equipped with intermediate
When producing fine denier products with a high number of stop as well as quick-release solutions.
filaments, it ensures higher yarn quality and extended yarn
evenness over time. Friction-intensive products, such as full- With selection of latest materials the lifetime of coatings are
dull or spun-dyed, that usually wear out these components improved, which
they are in contact with quickly, are processed with greater – Influences maintenance cycles positively
efficiency and with lower production costs. This is firstly – Reduces down time
due to non-existent slippage and secondly due to the godet – Increases machine efficiency
itself, which makes additional yarn-guiding elements or
wear-reducing components – such as yarn displacement in The W3 feed unit is equipped with a yarn displacement
the yarn path – superfluous. system as standard to reduce wear on coatings.

Other general advantages of godets include higher


consistency over process time and from position to position
as well as potentially lower energy consumption. By using
godets, energy savings of up to 5% can be achieved.

Energy Yarn Wear Products Process


consumption treatment parts Polymers flexibility

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

Heater / cooling combinations


Defining the right heater / cooling combination for a certain production range will optimize production. There are
technological and physical limits to be considered.

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

• Heat transfer of heating system • Production speed and capacity


• Heat deduction by cooling system • Energy consumption
• Friction • Yarn quality

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

8 DTY – Oerlikon Barmag


Heater Heater Titer range Preferred Energy Yarn Typically Typical application
Type length den operational saving treatment used for
range polymer

HTI 1.0 m 30 – 300 30 – 300 ++ ++ PET, PP, All kind of yarns


PTT depending on insert
type and combination

HTM 1.5 m 20 – 100 20 – 75 + + PET, PA, Fine yarn, micro- and


PP, PTT multifilament

HTM 2.0 m 30 – 300 30 – 200 o o PET, PA, Average commodities


PP, PTT

HTM 2.5 m 70 – 600 150 – 600 - - PET, PA, Coarse


PP, PTT
PET, PA, PP, Fine yarn, micro- and
HTM 1.5 m 20 – 200 20 – 150 + +
PTT multifilament
PET, PA, PP,
HTM 2.0 m 30 – 300 30 – 200 o o Average commodities
PTT

DTY – Oerlikon Barmag 9


Cooling solutions

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

HTM = Heat transfer medium


*HTI = High Temperature Insertion

10 DTY – Oerlikon Barmag


Tubes
Cooling tubes have been developed by Oerlikon Barmag in response to rising requirements in downstream texturing
in regard to process speed and friction. By using specially treated tubes Oerlikon Barmag developed cooling
components that cover a wide range of products, eliminate cool-outs and offer improved process speeds due to
reduced texturing zone length. The tubes are cooled by ambient air, but can also be connected to an air-conditioning
system to increase their cooling effect – so-called active cooling – for an even wider range of applications.

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

DTY – Oerlikon Barmag 11


Twist insertion

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.

All texturing units have the following characteristics in common:

• 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

Furthermore single driven aggregates offer...

• 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

The individually-driven type 8E texturing unit comprises


a fixed center design, which adds to the general
characteristics, extraordinary sturdiness and lifetime
evenness.

The FTS 53 aggregate simplifies string-up as a result of


its open-close function. When placing the yarn into the
aggregate, it can be single-handedly opened and closed
once the yarn is secured in the center. Thus, it potentially
improves string-up of very sensitive or complicated yarns.

12 DTY – Oerlikon Barmag


Quality management system

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!

UNITENS®1 production and classification of knot-free yarn packages,


The Online Tension Monitoring concept in the latest especially advantageous in conjunction with the automatic
generation with the unique combination of floating mean doffing function of the eAFK.
value, peak detection and CV evaluation, results in the
highest standard of online yarn quality control, statistics, The online yarn quality control system connected with the
quality and plant management. CreelManager represents a milestone in modern quality
monitoring. The package quality information is considerably
As an option for eFK and an integral part of the eAFK, this improved, which creates competitive advantages for
offers - in addition to the basic yarn quality evaluation and manufacturers. With the help of special sensors in the
quality grading of the produced yarn - essential data for the creel, the online yarn quality control system is provided with
best machine service and maintenance, all resulting in the information about supply package change. Hence, this
highest machine efficiency and productivity. information - with the knowledge about the supply package
- can trace issues back as far as individual spinning
The sophisticated, but easy-to-handle, system can be positions, which for the first time allows operators to monitor
combined with Oerlikon Barmag’s Plant Operation Center not only the performance of the DTY machine, but also of
(POC) software networking solution as well as with our the prior production step in POY spinning. The objective of
CreelManager system. the system is to integrate the entire process chain into a total
quality system (TQM).
CreelManager
The close link between online yarn quality control system
quality evaluation and Oerlikon Barmag’s CreelManager 1
UNITENS is an internationally registered trademark exclusively owned by
opens up – for the very first time – the possibility of Saurer Fibrevision Ltd., Macclesfield, UK

DTY – Oerlikon Barmag 13


Intermingling

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.

DTY – Oerlikon Barmag 15


Take-up zone

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.

16 DTY – Oerlikon Barmag


Single deck oiling Single deck oiling
Especially when processing PA yarns, even yarn tension Single deck oiling is the preferred high-end solution for the
is the key to quality production. To allow even process eAFK. Small and tightly covered oil troughs are located in
conditions from package to package as well as from deck to front of each take-up deck. Depending on the product and
deck, the eFK offers the possibility to implement so-called the process requirement, the application rollers have either
single deck oiling applying the kiss roller principle. a V groove along the yarn path or toothed rollers for applying
In front of each take-up deck an oiling device is located to the oil, dependent on the step-free setting of rotation speed.
ensure proper oil application for these demanding products.
Single deck oiling can be implemented whether the machine Pneumatically actuated, the yarn is either lifted out of the oil
cross section contains a secondary heater or not. applicator during doffing for oil-free transfer tails or it can be
fixed in this position for completely oil-free packages (e.g.
Oiling solutions for automatic machines - eAFK dye packages).

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.

DTY – Oerlikon Barmag 17


Take-up solutions

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.

Camshaft The individual position drives in process and maintenance


Over the years, Oerlikon Barmag has constantly worked on increase the flexibility during production and prevent
the further development of our camshaft take-up. The eFK’s unnecessary machine downtimes. A significantly lower
improved low vibration take-up section permits excellent noise level and a reduced number of mechanical parts,
package build. Uniform contact pressure is ensured by a easy maintenance and improved accessibility round off the
spring / lever system that is adjustable for different package mechanical improvements achieved by ATT.
densities. The eFK control system allows the selection of
a computer-calculated package formation program, which Another highlight is the control of yarn tension during
allows the best-possible package winding, formation and winding. In detail, this means the yarn tension profile during
unwinding performance for any type of yarn. winding cycle can be preselected in order to

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.

DTY – Oerlikon Barmag 19


Options / cross sections

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:

The Oerlikon Barmag elasthane covering device is an active • Conjugate (FDY)


unwinding device for the highest possible accuracy and best • Differential draw
unwinding performance. • Two-tone

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.

20 DTY – Oerlikon Barmag


Cross sections For mid to coarse denier, V or M cross sections can be
The flexibility of the modular machine structure in selected depending on the number of filaments and the final
conjunction with available high-end components has made product requirement. The V type is more suitable for the
Oerlikon Barmag the market leader and preferred machine mid denier, whereas the M type is clearly more suitable for
supplier for polyester and polyamide texturing machines. coarse denier with low number of filaments. When selecting
the components required for such a product portfolio,
Our texturing machines are - in terms of concept and each the right choice of feed system must also be taken into
component - developed with the final product, the relevant consideration.
process and application in mind. Cross sections have as
such evolved for all kinds of polymers but predominantly for For coarse to heavy denier the M type upper structure is the
polyester (PET) and polyamides (PA6 / PA6.6) with the best most suitable cross section for processing products with
possible processing in mind. high denier per filament and total denier. Due to draw forces
implemented by coarse products, a feed system shaft with
For processing of fine to mid or mid denier with a high nip roller must be selected.
number of filaments, the V cross section has been most
successful. When processing such yarns, length of the
texturing zone, suitable heating-cooling combination and
friction must be considered. Various combinations are
available using HTM and HTI heater technology.

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 • • • • • • •

DTY – Oerlikon Barmag 21


HTM upper structures
Fine to conventional denier, versatility, process speed, PET (inclusive PTT) / PA / PP / PLA.

Standard: V 2.0 DT / 1.1 P


The most versatile conventional cross section using HTM heater technology. Comprising a 2.0 m heater in combination
with a 1.1 cooling plate, this V cross section combines versatility and a wide operational window. It is suitable for most
commodities in a range between 30 to 300 den with best operational range between 50 and 220 den. Comprising
the straight yarn path of the V cross section, low tension and high draw ratios can be achieved resulting in excellent
manufacturing speeds, making this cross section a standard in the industry.

This cross section as single heater machine in conjunction with single deck
oiling is the preferred processing solution for mid denier polyamide yarns.

Versatility for efficient and high-quality production is achieved by

–  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.

V 2.0 DT / 0.85 (0.7) P


The most suitable cross section for processing fine denier polyamide yarns.
Comprising a 2.0 m Diphyl heater in combination with a 0.85 or alternatively
0.7 cooling plate this V cross section combines best possible processing
and highest process speed window. It is suitable for fine to mid denier in
a range between 20 or even lower to 150 den with best operational range
between 20 and 70 den. Comprising the straight yarn path of the V cross
section, low tension and high draw ratios can be achieved resulting in excellent
manufacturing speeds and high-end products.

Versatility for efficient and high-quality production is achieved by


–  Reduced friction
–  Elimination and optimization of contact points
–  Optimized cooling
–  Straight yarn path

Suitable for microfilament yarns and fine to mid denier.

22 DTY – Oerlikon Barmag


Coolflex: V 1.5 DT / 0.8 T
The Coolflex upper structure is optimized for processing very fine denier or products with very low filament count by means
of a shorter Diphyl heater in combination with a 0.8 m cooling tube. The 1.5 m heater allows energy savings of up to 15% in
comparison to the 2.0 m version. The 0.8 m cooling tube provides increased cooling capacity on the shorter length and can
be further optimized according to the product requirement by adjusting the wrapping angle. This results in an operational
window that especially favors fine denier and allows the processing of products even down to 20 den at even higher process
speeds than the standard cross section.

Improved processing of very fine and micro yarns is


achieved by

–  Optimized heater length


–  Improved and flexible cooling
–  Shortest possible texturing zone
–  Less stress to yarn with selected components

Suitable for super microfilament yarns and very fine to fine


denier, opening operational window for these products while
contributing energy saving.

Multispindle: V 2.0 DT / 1.1 P x 2


The multispindle upper structure allows the processing of double the number of yarn ends for the production of non-torque
yarns in a product range of fine to mid denier with low to conventional filament count. While plying yarns on conventional
machines the take-up capacity reduced by half. Hence, increasing the number of yarn ends for treatment before being plied
doubles the take-up capacity. The prerequisite for such processing is limiting the single yarn ends to 220 den, taking the final
denier of the plied yarn into consideration. This results in an operational window that favors fine to mid denier including low
single filament yarns.

Improved processing of plied fine to mid denier yarns is


achieved by

–  Doubling the number of yarn ends per heater


–  Doubling the number of cooling plates
–  Doubling the number of texturing positions

Suitable for microfilament yarns and fine to mid denier,


providing an operational window for plied products.

DTY – Oerlikon Barmag 23


HTI upper structures
Optimized operation window and versatility, highest process speed, PET / PP / PLA.

HTI: V 1.0 HT / 1.75 P


The electrical HTI heater can be used to widen the operation window. With its temperature range of
up to 550°C in addition to flexibility provided by Barmag’s patented insert technology, it allows the
processing of yarns at potentially higher process speeds. In order to compensate for the temperature
increase the cooling capacity has to be adapted proportionally. The conventional HTI version comprises
a 1.75 m cooling plate which provides a cooling capacity that allows the processing of fine to mid denier
at highest possible process speeds.

Versatility for efficient and high-quality production at highest process speeds is achieved by

–  Increased heating capacity


–  Increased cooling capacity
–  Opening the operational window while shortening the texturing zone to 2.75 m
–  Straight yarn path

Suitable for fine to mid and coarse denier in the 30 – 300 den range with an optimized operational
window.

24 DTY – Oerlikon Barmag


HTI coolflex 1.0 / 1.2 active: V 1.0 HT / 1.2 T
To further widen the operation window, the HTI heater is paired with Barmag’s cooling tube technology, that - while
shortening the texturing zone - increases the cooling capacity beyond the capacity of the 1.75 m plate for the most
demanding products. The ambient air cooling effect can be boosted by activating the air-conditioned cooling, hence
allowing the optimum processing of products with different processing requirements both flexibly and by eliminating all
bottlenecks at the highest possible process speed, which exceeds that of the conventional HTI version.

Versatility for efficient and high-quality production at highest


process speeds is achieved by

– Increased heating capacity


– Increased cooling capacity with active air cooling option
– Opening the operational window while shortening the
Texturing zone to 2.2 m
– Straight yarn path

Suitable for fine to mid and coarse denier in the 30 – 300


den range with an optimized operational window.

HTI coolflex 1.0 / 0.8 active: V 1.0 HT / 0.8 T


Similar to the Diphyl heater coolflex version, the HTI heater can be paired with the shorter cooling tube of 0.8 m length.
Although decreasing the cooling capacity limits the operation window, the shortening of the texturing zone leads to an
optimization for very fine denier and super micro yarns. The limitation is partially compensated with the active cooling
technology, also available in this version.

Versatility for efficient and high-quality production at highest


process speeds is achieved by

–  Increased heating capacity


–  Optimized cooling capacity with active air cooling option
–  Optimizing the operational window while shortening the
–  Texturing zone to 1.8 m
–  Straight yarn path

Suitable for very fine to mid denier in the range of 20 – 200


den with an optimized operational window.

DTY – Oerlikon Barmag 25


Plant Operation Center

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

26 DTY – Oerlikon Barmag


The “Job Reports” module The “Reports and Statistics” module

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

DTY – Oerlikon Barmag 27


Upstream processes

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.

28 DTY – Oerlikon Barmag


Polycondensation systems
The quality of raw materials is a decisive factor in the quality of the final product. Only vertically-
integrated companies control all levels of the value-added chain, all others are reliant on their suppliers.

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.

DTY – Oerlikon Barmag 29


Partnering for Performance

Our Customer Services department of Oerlikon Manmade Fibers segment has


one all-embracing mission: we want to make your production increasingly efficient
and productive, and your business increasingly competitive and profitable. To do
this, we offer you a close working relationship – Partnering for Performance

Our services for your success


Textile technologies are becoming ever more efficient and flexible, opening up
great opportunities to enhance your competitiveness. At the same time, this
progress accelerates the race in the market. To be able to keep up and react
swiftly to a changing market situation, it is important to maintain and expand your
technical capabilities and to utilise them properly.

To achieve these, we place emphasis on a close, trusting service partnership with


you to ensure reliable production and gain a technological edge, to secure your
investment and to guarantee success in the future. Together let us exploit the
strengths of our technologies for your business.

Our goal: your operational efficiency


Through our partnership we want to increase your operational efficiency to
best effect. With this in mind, we focus on optimising your operating and
manufacturing processes, your system and logistics management and the
acquisition of further skills by your staff. Your success grows with the interplay
of all the factors involved.

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.

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.
The service manuals permit a quicker and more efficient elimination of problems
via direct links. The e-Commerce system, well-known worldwide, is completely
integrated. The Engineering tool supports and accompanies the entire
engineering process from concept to the turn-key plant. Innovative ideas and new
solutions are added continuously. The latest encryption technology guarantees
the maximum data security at any time.

30 DTY – Oerlikon Barmag


Germany Indonesia Taiwan
Production Sites Service Site Service Site
Remscheid Bandung Taipei
Neumünster
Chemnitz India USA
Sales & Service Sites Sales & Service Site
China Mumbai Charlotte
Production, Engineering, Vadodara Service Site
Sales & Service Sites Dalton
Beijing Turkey
Wuxi Service Site
Suzhou Bursa • Main Oerlikon Manmade Fibers
Shanghai Service Network Stations plus more
Hong Kong than 120 agencies worldwide

DTY – Oerlikon Barmag 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
info.barmag@oerlikon.com

Oerlikon (China) Technology Co., Ltd.


No.9 Chang Yang Street
Suzhou Industrial Park
Jiangsu, 215024, P. R. China
Phone +86 512 8188 5902
Fax +86 512 8188 5988
dty.info.barmag@oerlikon.com
dty.service.barmag@oerlikon.com

The information supplied in this


brochure is for guidance only.
We reserve the right to modify it
at any time.
OBA 205 e / 9 / 2016

yaean design limited


Subject to changes