BCF-texturizing

NEUMAG
BCF-texturizing

part 1 : basics - texturizing process
NEUMAG
Page 3 Presentation
texturizing process
- Why texturizing?
yarn volume
yarn capability to recover after mechanical stress

Plug formation

decelaration of yarn because of force
bulking to yarn
continuous supply of yarn

Plug transport

dynamic air pressure of air feeded thru nozzle
thread momentum energy


Page 4 Presentation
Texturizing principles: Friction Texturizing
1
3
.
0
8
.
2
0
0
1



G
F
R
/
S
i



T
e
x
t
u
r
i
e
r
D

s
e
_
N
e
u
m
a
g
_
0
1
.
c
d
r
exhaust by
negative
pressure
plug is formed
by friction
flat yarn from
draw godets
inlet nozzle
hot air or steam inlet
yarn path
texturizing nozzle
outlet nozzle
inlet lamella chamber
area of crimp formation
exhaust
area of crimp setting
lamella chamber
lamellas
outlet lamella chamber
exit pipe
3D texturized yarn
Frictions - Texturizing

- Plug formation by friction force
- Control of outlet velocity of plug by force
equilibrium

Page 5 Presentation
Texturizing principles: Roller Texturizing
0
3
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0
9
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2
0
0
1



G
F
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/
S
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T
e
x
t
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i
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D

s
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_
B
a
r
m
a
g
_
0
1
.
c
d
r
inlet nozzle
hot air or steam inlet
yarn path
texturizing nozzle
outlet nozzle
inlet slotted chamber
area of crimp formation
exhaust
area of crimp setting
slotted chamber
outlet slotted chamber
exit pipe
3D texturized yarn
flat yarn from
draw godes
exhaust by
negative pressure
plug is formed and
controlled by
roller speed
roller
Roller - Texturizing

- Plug formation by air
blowing
- Control of outlet velocity of rolls

Page 6 Presentation
Bi Tex - principle
Principle

Combination of friction type process
start and roller typ production

easy plug formation by friction force

Adjustment an control of outlet
velocity using roller

No further need for vacuum after plug
formation
rolls
lamella
chamber
texturizing
nozzle
vacuum
BCF-texturizing

part 1 : basics - definitions
NEUMAG
Page 8 Presentation
Definitions 1
Nr. name description
1 Texturizing nozzle
nozzle which feeds the yarn in the
texturizing chamber
2 Texturizing nozzle : Yarn channel area where the yarn is feeded thru
3 Texturizing nozzle : yarn inlet
upper part of yarn channel of
texturizing nozzle
4 Texturizing nozzle : yarn outlet
bottom part of yarn channel of
texturizing nozzle;
transition from nozzle to lamella chamber
5 Texturizing nozzle : air channels inlets of air into yarn channel
6
Texturizing nozzle :
impingement point area where the yarn and the air is mixing
7 Stuffer box; texturizing chamber part where plug is formed
8 Lamella chamber type of stuffer box for friction texturizing
9 Lamella
friction : part of lamella chamber which
is in contact with yarn
10 Lamella edge
friction : part of lamella which is in
contact with yarn
11 Slotted chamber type of stuffer box for roller texturizing
12 vacuum; underpressure
underpressure of suction of air out of
lamella chamber
1
4
6
3
2
1
5
10
9
7 /
8
Page 9 Presentation
Definitions 2
13 Movable side door side of divided texturizing chamber
14 Fixed side fixed side of divided texturizing chamber
15 Rolls feeding rolls in roller texturizing
16 Lowest plug formation vacuum
slightest difference ambient pressure -
vacuum in text. chamber where plug
is formed
17 Yarn tension of nozzle
yarn tension between godet and
texturizing nozzle
18 Plaiting angle
point on cooling drum where
plug is distract
19 Twist of nozzle
twist of yarn between godet an nozzle
because of nozzle
20 Crimp
length difference between streched
and non-streched yarn
21 p(plug-formation)
counterpressure for plugbuilding ( not
permanent )
22 outlet pipe
for Bitex and friction : giudes the plup to
rolls /cooling drum
Page 10 Presentation
Definitions 3 : Bitex & friction
yarn tension / plug density vs. vacuum
0
20
40
60
80
100
120
140
160
-80 -70 -60 -50 -40 -30 -20 -10 0
vacuum
y
a
r
n

t
e
n
s
i
o
n

/

p
l
u
g

d
e
n
s
i
t
y
plug density
yarn tension
no plug
lowest
possible
vacuum
break
because of
choking the
nozzle
best operation
point
5-10
mbar
below
lowest
possible
vacuum
Page 11 Presentation
Definitions 4 : Bitex & roller
yarn tension / plug density vs. roller speed
50
60
70
80
90
100
110
120
130
140
150
40 45 50 55 60 65 70 75 80 85
roller speed
y
a
r
n

t
e
n
s
i
o
n

/

p
l
u
g

d
e
n
s
i
t
y
plug density
yarn tension
no plug
fastest
roller speed
break
because of
choking the
nozzle
lowest roller
speed
5-10 cN
5-10 %
best
operatio
n point
BCF-texturizing

part 1 : adjusting parameters
- thread pre-treatment
NEUMAG

Page 13 Presentation
Thread pre-treatments 1
- Draw ratio
influences capability to preserve crimp under tension
the higher the stretching of the yarn the lower the
elongation
PP should be stretched to the maximum
not overstretching - yarn breaks
regular checks because of polymer ( elongation; tenacity )


Spin finish

influence friction in texturizing in chamber
influence company of filaments
influence tendency to glue on the godet
eveness is important

Note : each process has its own dependencies and optimums. Shown graphs
and values are not transferable
Page 14 Presentation
Thread pre treatments 2

yarn temperature

influence tenacity of yarn during texturizing
influence the capability of crimping the yarn
influenced by godet temperature
godet temperature influence mainly crimp / shrinkage
heat transfer coefficient : clean godet surfaces


M6_1 : crimp vs. godet temperature
PA6; 1340 dtex; 3200 m/min
10
10,5
11
11,5
12
12,5
13
13,5
14
14,5
15
15,5
16
16,5
17
150 160 170 180 190 200 210
godet temperatur [C]
c
r
i
m
p

[
%
]
BCF-texturizing

part 1 : adjusting parameters
- in texturizing head
NEUMAG

Page 16 Presentation
Adjusting parameters 01
- Texturizing nozzle
temperature
influence temperature in lamella chamber
influence crimp / shrinkage ( not as strong as godet
temperature
if to high melting of yarn in lamella chamber after break

Texturizing nozzle pressure

influence yarn tension ( process stability)
influence twist ( process stability )
influence slightly the crimp
to the nozzle pressure has found out the optimal
vacuum



M6_2: crimp vs. Temperature of texturizing air
t(nozzle) T(nozzle)
PA6; 1340 dtex; 3200 m/min
10
10,5
11
11,5
12
12,5
13
13,5
14
14,5
15
15,5
16
16,5
17
180 185 190 195 200 205 210 215 220 225 230 235 240
Temperature of texturizing air T(nozzle) in C
c
r
i
m
p

i
n

%
Page 17 Presentation
Adjusting parameters 02
- vacuum chamber / roller speed
influence slightly crimp and shrinkage
influence process stability ( evaluate min - max. )
Bitex : vacuum time approx. 10-15 sec.

texturizing nozzle geometry

influence yarn tension and process stability
influence crimp and shrinkage
influence mixing ( tricolor )
Bitex & friction : 2 different sizes; rolls : 2

lamella chamber geometry

influence process stability
influence crimp and shrinkage
Bitex & friction : 2 different sizes; rolls : 2




PA6 1250dtex
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
20 30 40 50 60 70 80 90 100 110
mbar
%
Mitte - Shrinkage
Mitte - crimp
Polynomisch (Mitte - crimp)
Polynomisch (Mitte -
Shrinkage)
Page 18 Presentation
Adjusting parameters 03
- vacuum and speed cooling drum

vacuum influence capability to cool the yarn
determines plug density on cooling drum
Completely filled cooling drum groove to increase
cooling time and equalize air flow (especially needed
for PP)


crimp as function of cooling time
-5,0
5,0
15,0
0,0 1,0 2,0 3,0 4,0 5,0
cooling time in sec.
c
r
i
m
p

o
f

B
C
F

-

y
a
r
n
new
standard
Page 19 Presentation
Adjusting parameters 04

plaiting angle / yarn tension behind cooling drum


influence process stability ( tangeling)
influence crimp by possible crimp loss
pulling out crimp if yarn isnt cooled proper
Important is yarn tension after cooling drum and
process stability



BCF-texturizing

part 2 :
maintenance and trouble shooting
NEUMAG
Page 21 Presentation
indicators
all

experience/ maintenance intervalls
efficiency of process
increased number of yarn breaks
loss of yarn tension before nozzle
change of twist between godet and texturizing
nozzle
changings of plaiting angle of cooling drum
( depends on process)
changings of crimp
changings of shrinkage


Page 22 Presentation
cleaning 1
all

deposits in texturizing nozzle
(yarn channel and air inlet )
deposits in texturizing support
deposits in cooling drum suction vacuum
drops
deposits on godets

Bitex & Friction
deposits on lamella
deposits in lamella chamber housing / slotted
chamber
deposits in vacuum suction vacuum fluctuation


Page 23 Presentation
cleaning 2
Page 24 Presentation
Tear and wear of yarn contact parts
all: Texturizing nozzles
impingement point
yarn outlet
yarn inlet ( tricolor )
step in yarn channel







Bitex & Friction:
lamellas
upper part of lamella edge
Page 25 Presentation
Frequent damages 1
all / Texturizing nozzle

Burr in yarn channel or air channels
Yarn outlet of texturizing nozzle deformed
Excess length of wrong screws over
contact level mark on door nozzle half

all
Contact surfaces of texturizing
nozzle or lamella chamber not
levelled or flat




Page 26 Presentation
Frequent damages 2
Bitex & Friction : lamellas

lamellas deformed or bended
Lamella edge with burrs
Lamella surface grated
Lamella chamber housing dented excess length on contact area
different grinding direction of lamellas ( sides ) - for very sensitive
processes
all : other problems

thread guides over texturizer damaged
chamber crest twisted
Pairing of texturizing nozzles and lamella chambers

Bitex & Roll :
damage / burr of cogs of feeding rolls (in most cases by cutting yarn
from the feeding rolls
burrs in ground of slotted chamber ( slit )





Page 27 Presentation
component check
all
Sight inspection of texturizing nozzles
matching numbers of nozzle; matching numbers of lamella chambers /
slotted chambers
Sight inspecition of individual lamella (bending, finger nail test: burr on
cutter,..) or slotted chamber
Bitex & Friction
Lamella chamber: Twisting of chamber crest





Page 28 Presentation
component check
Roll

Flat contact surface of nozzle and slotted chamber
No step between nozzle and slotted chamber
Nozzle and slotted chamber centered
Nozzle and thread guides centered
No deformation / damages of nozzle and slotted chamber




Page 29 Presentation
component check
Bitex & Friction
Lamella chamber with mounted lamella: sight
inspection on deformed lamella and dents
Contact nozzle : yarn outlet - lamella slant
all
Pressure foil "pressurex" test of force
distribution
www.pressurex.com ;
roller : 28-85 psi
friction : 70-350psi





contact
Page 30 Presentation
process check
all : on the texturizing head
Centrical yarn inlet in texturizing nozzle ( guide )
Twist of yarn between godet and nozzle
Yarn tension before nozzle and after cooling drum
Bitex & Friction
Underpressure fluctuations (mano-
meter
and pressure gauge)
Lowest plug formation vacuum
Underpressure / vacuum
Bitex & Roller
Adjustment of roller speed
all: yarn
Crimp
Shrinkage
Tenacity
Elongation





Page 31 Presentation
process check
all
on position

Quench air velocities ( for sensitive processes)

Spin finish / yarn in spin finish guide

Godet hood closed

Plaiting angle / point on cooling drum

Sufficient pressure before spin pack because
of avoiding small filaments on the outside
areas