Issue 8 – April 2008

Textile Technology
The technology magazine
for the manmade
fiber industry
Imprint Publisher: Oerlikon Barmag Zweigniederlassung der Oerlikon Textile
GmbH & Co. KG / Leverkuser Strasse 65 / D-42897 Remscheid, Germany /
Phone: +49 2191 67-0 / Fax: +49 2191 67-1204 / pr.barmag@oerlikon.com /
www.oerlikontextile.de / Graphics and design: Studio 45 / Print: Koch Print Media,
Remscheid, Germany / Edition: 3,000 copies / Textile Technology appears once
a year in English
Table of contents

WINGS – the innovation in POY production 4

MPS CoolFlex – the benefit of a controlled

cooling zone 8

COCOON – creating added value with

variants and options 12

Total Solutions from a single source 20

Textile Technology – Issue 8 

 WINGS – the innovation in POY production

Over the past few years, the efficient production of POY has been predominantly deter-
mined by an increase in the thread count per winding position. From an original 2 threads,
the thread count has now been increased to up to 20 threads per spinning position. The
preferred package weight for the texturing process is 15 kg/package.

The cost effectiveness of a modern spinning plant is influenced by many factors, of which the following
are the most important:
- Yarn quality
- Productivity
Dipl.-Ing.
- Efficiency
Markus Reichwein
- Space requirement
- Energy consumption
- Personnel requirement

WINGS – the idea

These form the basis of WINGS, Oerlikon Barmag’s new POY solution. WINGS was developed with the
objective of increasing the productivity, the cost effectiveness and the quality of POY systems.

WINGS – Winding INtegrated Godet Solution – bears the solution in its very name. The winder becomes a
complete take-up machine. Hence, the spatial separation of godets and winders and a separate take-up
unit common today are a thing of the past.
Dipl.-Inform.
Jutta Stehr The basis of this new concept is the ACW winder, which is being successfully used in countless spinning
systems throughout the world. The new layout of the godets, the tangling unit and the optimally-inte-
grated Online Monitoring System (OLM) offers a comprehensive series of benefits maintaining the proven
ACW technology such as bi-rotor systems and yarn deposit and ribbon breaking methods.

Fig. 1
WINGS is a complete
take-up machine

 Textile Technology – Issue 8

High yarn quality
WINGS systematically pursues the narrowing of the yarn angle within the yarn path. Points with a high
wrapping angle have been equipped with rotating and hence friction-free yarn guides. The sum of all
yarn deflection angles within the drawing zone is only approx. 7 degrees. This represents a considerable
reduction of yarn deflection angles of 28°-30° when compared to a conventional POY drawing zone.

Fig. 2
The WINGS concept
significantly reduces the
yarn deflection angles

As a result, the WINGS system achieves a considerable improvement in the yarn evenness. For example,
the cV% values of the deviations of the threads among each other in terms of strength and stretch has
been improved by 20-40% in comparison to a conventional ACW with identical POY products and overall
conditions. This is clearly demonstrated in the following example.

Fig. 3
ACW take-up WINGS take-up Benchmark ACW
Product 120f72 120f72 versus WINGS

Count [dtex] 132 132

Tenacity [cN/dtex] 2.41 2.43
Tenacity [CV%] 2.9 1.6
Elongation max. force [%] 128 128
Elongation max. force [CV%] 2.9 1.6

Textile Technology – Issue 8 

 Higher productivity and efficiency
In conventional spinning systems, the drawing zone and take-up unit make up two separate levels be-
neath the spinning plant. Correspondingly, the yarn string-up is normally carried out by two operators.
WINGS, on the other hand, is operated from a single level and position and all elements are ergonomic in
design and layout. This significantly reduces the time required for yarn string-up by more than 50% – time
in which top-quality POY yarn can be manufactured.

At the same time, the risk of string-up errors is also radically reduced by the new concept. The – in
comparison to a conventional take-up unit – halving of the string-up time and the concept, consciously
designed for error-tolerant operation, result in a considerable waste reduction within the drawing zone.

Furthermore, the string-up process now only requires one operator, who can check all drawing zone
components at a single glance. The, in total, approx. 20% lower workload for the operator means that the
second operator – required until now – can be deployed for other tasks.

Fig. 4
One level instead of
two: WINGS makes
operation much easier

 Textile Technology – Issue 8

WINGS simplifies and shortens the installation of the spinning system. WINGS is supplied as a com-
pletely-assembled, pre-installed and tested unit. All that is required onsite is for the unit to be connected
to power and compressed air sources. This not only reduces the assembly costs for our customers, it
also results – in addition to reduced errors – in a faster production start and hence allows customers to
start profitable operation of their spinning plant sooner.

Furthermore, there are considerably fewer requirements for the building in the case of the WINGS con-
cept. Conventional layouts require the elaborate installation of floor tracks and the almost millimeter-ac-
curate alignment of the drawing unit and winder. As a result of an integrated, self-bearing frame, spinning
positions equipped with WINGS make no special demands on the evenness of the floor and provide an
optimal process and, hence, product quality even in the case of slight floor unevenness. This considerably
reduces the costs for accurate alignment.

Lower space requirements and a more compact building

WINGS is an autonomous unit with integrated control box and follows a concept of independent single-
position control units.

Dispensing with the drawing zone also permits greater freedom for the positioning of the machines.
Here, producers can continue to plan on the basis of a conventional layout. However, the WINGS design
enables a considerably tighter spinning plant layout, with lower space requirements of up to 35% in com-
parison with conventional systems. Hence, a new spinning plant building for a given production capacity
can be planned with a considerably more compact footprint from the very start, also providing investment
savings at the same time.

In the case of modern polymerization units designed for future capacities of more than 600 tons/day, the
compact layout considerably reduces the line lengths and hence ensures shorter residence times. In par-
ticular, this results in considerably shorter residence time differences throughout the entire system.

As a result of the reduced height of the components, integrating WINGS into an existing spinning plant
building offers benefits. The greater distance between the quenching unit and take-up unit results in a nar-
rower deflection angle and hence has a positive impact on the yarn quality. In the case of older buildings
with lower ceiling heights, in which retrofitting with a conventional drawing zone would be impossible, the
original deflection angle can be extensively maintained. For this reason, even existing spinning plants can
be updated with WINGS and upgraded to include the latest process know-how.

Energy efficiency
From the very outset, WINGS was systematically designed with the use of cost-saving components for ef-
ficient POY production. For example, using a new tangling jet concept considerably reduces the tangling
unit’s air consumption.

Summary
With WINGS, Oerlikon Barmag is breaking completely new ground in terms of increasing POY production
efficiency. As a result of the improved yarn evenness, the new concept enables not only an optimization
of the POY quality and hence also the DTY quality, it also – in conjunction with Oerlikon Barmag spinning
plant concepts such as the EvoQuench unit for microfilaments – reduces the investment and manufactur-
ing costs of an economic and high-quality POY spinning plant process.

Textile Technology – Issue 8 

 MPS CoolFlex – the benefit of a controlled
cooling zone

The increasing demand for fine denier filament yarns is constantly requiring new tex-
turing solutions. The MPS CoolFlex – a variant of the Multi Purpose Superflex (MPS)
launched in 2003 – is Oerlikon Barmag’s response to this demand. Premiered at the
ITMA 2007 in Munich, the MPS CoolFlex proved a sales success even during the trade
fair.

What is so special about the MPS CoolFlex? The focus was placed on the altered textur-
ing zone – a new development that is extremely short in design. This allows the overall
height of the texturing machine to be considerably lower than to date and is only one of
the benefits offered by this new concept.
Dipl.-Ing.
Stephan Faulstich

Fig. 1
The MPS CoolFlex –
a model variant of the
Multi Purpose Super-
flex – made a huge
impact even on the first
day of the ITMA 2007

 Textile Technology – Issue 8

The texturing zone
The advantages of a short texturing zone producing fine denier yarns are obvious. Less friction means
higher process speeds. To pass such obstacles as heat transfer and cooling power, Oerlikon Barmag had
already invested considerable effort in developing an electrical heater and a cooling pipe in the past.

With the aim of considerably shortening the texturing zone, the development focus was placed on full-
contact insert technology and an adjustable cooling pipe. The result is revealed in the MPS CoolFlex’s
upper structure.

The short (1-meter) electrical heater with a full-contact insert

Using a full-contact insert inside this 1-meter electrical heater produces a yarn character very similar to
that manufactured using a conventional 2-meter diphyl heater. At the same time, the energy consumption
is dramatically reduced.

The adjustable short (0.8m) cooling pipe

There are many advantages offered by a cooling pipe: a more effective heat transfer resulting from the
enlarged surface of the cooling pipe ensures an efficient cooling effect. However, the real advantage lies
in the possibility of adjusting the contact area.

Clinch angle of the cooling pipe depending on the titer Fig. 2

Textile Technology – Issue 8 

 This concept achieves a new dimension in controlling stability and hence the resulting quality. By adjusting
the yarn contact area (change of diameter) on the cooling pipe, the cooling efficiency and friction can be
set to the requirements of the yarn. Figure 2 shows the connection between yarn titer and cooling pipe
clinch based on optimal friction and the highest stability.

Furthermore, the new texturing zone concept provides useful benefits for quality control. Our examina-
tions have revealed a direct, defined correlation between the yarn path stability in the texturing zone and
the associated friction in order to achieve the best quality.

To visualize this correlation, Oerlikon Barmag has developed a parameter called the “quality number”.
This number is based on the elongation, tenacity and shrinkage yarn characteristics and converted into
mathematical form.

For yarn manufacturers, this provides the correct clinch setting in a simple manner within the normal trial
procedure. Figure 3 shows the progression of the quality dependant on the clinch angle.

Fig. 3 Progression of the quality depending on the clinch angle

10 Textile Technology – Issue 8

Conclusion
The short texturing zone in conjunction with the possibility of securing the best setting of the yarn con-
tact within the cooling zone can result in production speeds that are up to 40% higher without the risk of
lowering the quality.

With the highest level of flexibility, a reduction in energy consumption of up to 30% and the best opera-
tor ergonomics, the MPS CoolFlex is setting new standards in fine denier production. As a result, MPS
CoolFlex guarantees an extremely short Return of Investment (ROI) for the yarn producer.

Textile Technology – Issue 8 11

 COCOON – creating added value with
variants and options

The market launch of the COCOON in the middle of 2006 opened up a new chapter in
manual texturing. The COCOON allows yarn manufacturers to produce even the highest
quality and complex yarns on a manual texturing machine. This has been confirmed by
the production results provided by numerous customers throughout the world, who have
already started production with these machines.

By integrating state-of-the-art engineering and new technologies, the COCOON offers three decisive
benefits:
- Lower resource consumption (energy, wear parts, manpower)
- Improved ergonomics (optimized service / reduced noise development)
Dipl.-Ing. - Optimized process zones (best-possible treatment of different, and particularly special, yarn types)
Marcus Herzberg

On the machine side, this is achieved with the, for manual texturing machines, unique godet drives, among
other things. This modern design creates a decisive competitive edge for texturing plants within a volatile
market. The following describes the variants and options of the COCOON, providing yarn manufacturers
with “value added” and “unique selling prepositions” and enabling them to distinguish themselves from
their competitors with special products.

Variants
HTI
Following the V-Dowtherm variant with 2-m Dowtherm heaters, the upper structure now also comes in the
V-HTI configuration with 1-m electrical heater and 1.75-m cooling plate. This variant draws on Oerlikon
Oliver Lemke Barmag’s patented HTI heater in its latest design. This incorporates the flexible insert concept, which is
only available for Oerlikon Barmag’s heaters. The most recent heater developments have allowed the HTI
heater to include the benefits offered by a contact heater. Hence, the HTI variant now covers a broader
range of processes. COCOON customers can now choose between these two upper structure variants
based in the 2-heater machine.

Split version
The split version of the COCOON allows individual operation of both machine sides. The 120 positions on
each side of the machine can be operated independently of the other, including all the settings required
for the respective process. Hence, two completely different yarns can be manufactured within the process
window of the machine or the upper structure.

The split version occupies a special place among the variants and options. It can be optionally ordered
for the Dowtherm and HTI variants for the 2-heater machine, but not sensibly retrofitted as in the case of
the options.

This design is also a very interesting alternative for yarn manufacturers as even the basic version of the
COCOON is designed with a separation of many of the mechanical and electrical functions. The back-
ground to this is the COCOON’s new control and drive concept. Hence, considerable value added is
created with very low effort. Customers have picked this as their most popular choice, thereby establish-
ing it as the standard for efficient and flexible production.

PA version (single-heater)
The COCOON product range has meanwhile grown to include a concept for a special nylon variant as
a “single heater version”. Hence the godets and the ATT also open the door to improving the product
in this market segment. Dispensing with the G3 godet and the second heater for production using the
investment-optimized machine is only possible in the split version. The reason for this is the COCOON’s
above-described design concept.

12 Textile Technology – Issue 8

 Fig. 1
Cross-section of the
COCOON variant for
polyamide

The new drive concept with godets is able to cater to the requirements of particularly gentle yarn handling
especially in the fine-denier sector. The new and further-optimized layout of G2, G2X and coning oiling ap-
plication additionally supports this concept. The special positioning of the G2X within the direct yarn path
only marginally influences the construction height despite the considerably improved process control and
separation of the tangling and winding processes. Even the, during the winding process, difficult PA yarns
can be optimally prepared for further processing using the ATT take-up unit. For example, downstream
processes not possible to date can be carried out, hence reducing conversion costs. This also applies to
all other materials, such as PP, PTT and PLA, which require a process behavior with special demands on
the texturing machine, in particular during winding.

When the market also accepts the integration of state-of-the-art components in the classical PA fine-
denier DTY sector for manual texturing machines, this concept will be implemented into daily production
processes.

Options
In addition to the COCOON components integrated as standard, such as the UNITENS, as a quality
monitoring system, the G2X, for optimal control of the tangling process, and the ATT, for perfect package
build, the COCOON can be expanded to include various options that can all be retrofitted and combined
(dependent on the specific situation). Here, we can distinguish between options that expand the process
scope, i.e. the number of potential different yarn types, and those that expand the general capabilities of
the COCOON in production.
Textile Technology – Issue 8 13
 G1.1 and G1.2 additional drives with additional equipment
The COCOON’s design offers sufficient scope for the attachment of various additional components. Cor-
respondingly, the processes we are familiar with from the FK6-1000 can be transferred to the COCOON
concept with additional feeding units and components. Here, the COCOON’s possibilities and benefits
are fully retained and the quality and functionality are even increased.

The first basic component that can be used as an additional element within the machine is a further “feed-
ing unit”. This is designed as an additional G1.1 godet beam for the COCOON and not only enables the
operation of two different draw units for parallel threads, but also the processing of composite yarns in the
texturing process. Further possibilities include pre-drawing or tangling with a defined input tension, as well
as additional yarn heat treatments prior to the texturing process with a “hot pin”. Also optional is a second,
additional G1.2 feeding unit, which is only required for special combinations however. The allocations of
the various components and processes are shown in the table.

Processes with bi-component and linen yarn types can be run even without additional equipment, as only
a special POY or specific texturing parameter settings, including friction, are required. However, the com-
binations listed in the table are also possible, whereby special yarn types are created. Composite yarns
with an FDY as second feeder material has established itself as standard, particularly for bi-component
yarns. Oerlikon Barmag’s process experts can also support yarn manufacturers in the production of such
specialty yarns.

Fig. 2
Added value products
Necessary additional equipment
on COCOON
Yarntype G1 1 EL- Normal Effect Hotpin Heater- Exten- Combi-
device jet jet clipse ded nation
creel possible
with

1 Bicomponent 3/5
(conjugate or
orange type)

2 LinienType 5/7

3 Pre-interlace
(POY) X all

4 Two-Tone X X

5 Composite
(FDY or other) X X

6 Thick-Thin X X

7 Pre-interlace
(Effect) X X optional

8 Diff Shrinkage X X X

9 Composite (EL) X

14 Textile Technology – Issue 8

 Fig. 3
COCOON G1.1
godet beam

When an additional yarn component, for example an FDY or a POY made from a different material, is used
in the process, this always requires an additional creel or another supply method for these materials. For
various processes, this variant can be optionally used with a further supply material for the process.

The COCOON’s drive concept, with godets and single drives, provides further advantages. Special
processes incorporating several yarn components are generally more likely to suffer a greater risk of yarn
breaks on all texturing machines. With the COCOON, however, removing yarn wraps is easy and safe, as
each godet drive can be switched off separately.

As a result of its godet drive, the COCOON offers a more constant yarn quality over a longer period of
time, and hence opens up the possibility of expanding maintenance intervals. The maintenance cycles,
normally determined by wear to the nip rolls, are considerably longer or maintenance is no longer even
required at all. The system also provides greater position evenness from position to position. This prevents
any negative impact on the process – particularly following a lot change – in the case of special processes.
The overall product quality is increased and an accurate product reproducibility is ensured at all times.

Stand-alone PC cabinet
The stand-alone PC cabinet is an option for more flexible positioning in the event of difficult spaces. Proc-
esses already established in production can be retained, therefore integrating COCOON machines into an
existing production facility or into an existing building is uncritical.
Textile Technology – Issue 8 15
Fig. 4
The elastane unit is
optional available for
COCOON

16 Textile Technology – Issue 8

Elastane device
The technology used in the active elastane unit integrated into the MPS machine in 2005 has also been
deployed in the COCOON and adapted to the COCOON’s basic construction. The fundamental benefits
vis-à-vis a passive additional unit and the improvements – specifically yarn guiding and elastane package
handling – were taken from the MPS. Hence, the additional elastane unit for the COCOON has the follow-
ing properties and customer benefits:
- Technology with active feeding system
- Drive concept in line with COCOON
- Integrated elastane process
- Lower manufacturing costs
- Better yarn quality

Subsequent machine upgrading is possible with this additional equipment, as all COCOON machines are
prepared for this conversion. Therefore, customers can opt to retrofit in accordance with their production
requirements and market demands at any time. The elastane unit can also be combined with one ad-
ditional G1.1 unit.

The elastane unit described here is already in operation with numerous customers manufacturing various
yarn types with their machines, including the finest texturing yarns (e.g. 22 and 33 dtex PA) in combination
with fine elastane threads (e.g. 20 den). The product spectrum, with which we have been familiar to date
from two-step processes, can now also be covered by a 1-step process.

ATT
A particular highlight of every COCOON is the standard ATT traverse system (Advanced Take-Up Tech-
nology), with currently more than 30,000 positions successfully operating in various Oerlikon Barmag
texturing machines. This traverse system eliminates the limitations of standard take-up units frequently
ascertained in the past. The ATT traverse system’s benefits are fully revealed particularly in the case of
special yarns, one example being the extreme PTT shrinkage behavior following the texturing process on
the DTY package, which can be compensated by the special features of the ATT take-up.

As standard, the ATT traverse system considerably improves the quality of the textured package, hence
creating significant value added for further processing. Therefore, all texturers using the ATT are able to
distinguish their products from their competitors. The ATT permits the winding of DTY packages of 20-
30% greater weight for the same volume.

For example, the functionality for dye packages can be further increased with the FlexiDye option for the
ATT. The following features are included:
- Round edges
- Dye layer inside with additional endless transfer tail
- Protective layer outside
- Doff signal on diameter

All in all, texturing plants can manufacture dye packages that provide considerable value added in further
processing, permitting direct dying without rewinding with simultaneously higher package volume, for
example.

Textile Technology – Issue 8 17

Fig. 5
The functionality for
dye packages can be
further increased with
the FlexiDye option

A feature only made possible by the ATT, displays the doff signaling in terms of diameter in the case of
manual machines. Hence, yarn manufacturers can provide their products with a further quality feature.

As an option, the ATT in the COCOON can be expanded to include the Taper Marker quality function.
Here, the additional marker winding function we are familiar with from the MPS has been transferred to
the functional options of the COCOON’s manual take-up. The finished DTY package is marked to indicate
the properties “full bobbin” and “C-quality” directly on the package itself, hence permitting the operator to
immediately quality grade even without a PC or label on the respective package. This does not influence
the take-off properties in further processing.

Outlook
In addition to the above-presented variants, the COCOON concept already takes the introduction of
further variants into consideration. On the one hand, these are the implementation of upper structure
variants from automatic machines or, on the other hand, the integration of a multi-spindle version into the
COCOON’s product range. The scope, the contents and the time scale for the next steps are oriented on
future customer needs and market requirements.

The COCOON concept includes the expansion from 10 to 12 sections and hence 288 positions per
machine. In particular, this affects the control unit and the central functions, whose performance has
already been geared to the raised requirements. Increasing the number of production positions for the
same central scope ensures optimized space requirements and results in a more favorable investment
per position.

Ultra-cap-buffering
In addition to the standard integrated kinetic buffer, the development includes the option of a buffer for the
machine’s internal power supply ensuring uninterrupted operation. This ensures a continuous production
process without any loss of yarn quality for a certain period of time. Depending on the power consump-
18 Textile Technology – Issue 8
tion, the bridging time is in excess of 1 second. This is achieved by ensuring a constant power supply
to all drives in the event of a power outage using state-of-the-art, high-performance capacitors. In those
areas with frequent power outages, amortization is possible within one year.

Summary
The available variants and the available options further increase the value of the COCOON for yarn manu-
facturers and their customers. Special products and an optimized production process allow manufactur-
ers to distinguish themselves from their competitors. The COCOON concept uses new standards, as it
offers benefits for both DTY manufacturers and in further processing.

The COCOON also provides changes in manual texturing. The systematic use of all the engineering ben-
efits has created a product that corresponds to all market requirements. With the COCOON, the efficient
and economic production of top-quality yarns is now no longer only possible using automatic machines.

COCOON, with its variants and options, was developed on the basis of the teamwork, integrity, excel-
lence and innovation values. Innovative new components such as the ATT and godet units and the
excellent quality of the textured yarns characterize the COCOON as the product of a well-functioning
interdisciplinary team.

As a future-oriented company with a responsible, respectful approach to nature and natural resources,
energy conservation plays a particularly important role in Oerlikon Textile’s research and development.
Machines and systems with considerably lower energy consumption vis-à-vis the market standard (on
average 20 to 25% here) are awarded Oerlikon Textile quality control’s “e-save” certification. COCOON is
e-save certified.

Textile Technology – Issue 8 19

 Total Solutions from a single source

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. Many years of experience in textile
machine construction and Oerlikon Textiles’ strong global network form a solid basis and
the perfect qualification for Oerlikon Barmag as a provider of entire process chain for
manmade fibers.

Many textile producers have to import intermediate products such as granulate, partially oriented yarn
(POY) or fully oriented yarn (FDY). This leaves them little influence over delivery times or on yarn quality.
However, having their own polymerization, spinning/draw-winding and draw texturing equipment opens
Dipl.-Ing.
up the opportunity to produce yarn independently of intermediate product deliveries and to determine and
Fareed Muzadique
control the yarn and final products. This enables a quick, flexible response to any changes in the market.
A harmonized chain of polymerization, spinning and texturing machines allows efficient production, and
this increases the added value for the customer.

In plant engineering and construction, the term ‘plant design’ means turnkey construction. This means
that, from the feasibility studies through to the project implementation, the customer receives all services
from a single source.

Efficient workflows
Most state-of-the-art resources are used by experienced project engineers for the preparation of the
necessary documentation. Combining machine and plant construction with engineering enables precise
tailoring to the requirements of the project. The result is high-quality engineering.

20 Textile Technology – Issue 8

Direct access to the necessary data, along with the possibility of creating manufacturing documents as
well, makes it possible to prepare the required documents with the utmost efficiency. This offers the user
reliable information early on, reducing adjustment services to a minimum. Last but not least, a properly
prepared engineering documentation means shorter assembly and commissioning times.

Comprehensive and transparent documentation

The documents prepared within the Oerlikon Barmag engineering framework give the customers maxi-
mum transparency with regard to the scope of delivery, the quality of the plants and the project procedure.

The preparation of comprehensive specifications for the direct purchasing through the customer (if re-
quired) is part of the range of services, as are prospective calculations for the consumption of auxiliary
production materials. Auxiliary aggregates, regardless of whether delivered by Oerlikon Barmag engineer-
ing or provided by the customer, are included in the Oerlikon Barmag engineering and are integrated into
the general project.

Data-based engineering tools

The high functionality of today’s available database-related CAD software enables a quick and efficient
preparation of the documentation. Naturally, this networks with SAP and CAD for mechanical and electro-
technical design.

Innovation – straight from the Oerlikon Barmag R&D Center

The roots of the Oerlikon Barmag R&D Center date back to 1969. At the time, Oerlikon Barmag was
installing the first polyester POY spinning plant, which was designed to help fully develop the Oerlikon
Barmag SW4 high-speed take-up winder.

Textile Technology – Issue 8 21

 Today, the R&D Center for spinning machines is the largest of its kind in the world, and is equipped with
10 lines for all melt spinning processes (POY, FDY, HOY, industrial yarn, HMLS, spun-textured yarn and
bi-components). The testing facilities are updated continually. They offer yarn producers innovative tech-
nology, including granulate drying and a second granulate condensing process for further development
work on machine components. An experienced team is on hand for the operation and maintenance of
the systems. Organization and structuring of the R&D Center offer optimal conditions for all customer
requirements.

Total Solutions for all applications

From poly-condensation to polyester textile yarn POY, FDY, HOY
– Continuous poly-condensation starting from PTA and MEG
– unique competence for the full product chain "poly-condensation – transfer line – direct spinning"
– spinning and winding systems up to 24 ends per position depending on the final product

Dyed draw-textured yarn

– ATT Texturing
− optimized shape (e.g. round edge)
− even package density
− optimized package diameter
− inside and outside protective layers
− endless transfer tail

– Direct dyeing
− uniform direct dyeing of critical products
− omission of intermediate rewinding process
− cost reduction for tubes, packing and logistics
− bigger size of dye packages
− uniform and even dyeing results
− full scope of dye house equipment from one source

Spandex
– Semi-continuous polymerization and spinning plant
– Latest technology in dry spinning with 32 ends per cell
– Flexible production range allows quick reaction to market needs
– German-Italian engineering with European, and local, equipment
– High yarn quality and product innovation capability
– Reliable performance and product guarantees
– Partnership for yarn fabric and development and much more

22 Textile Technology – Issue 8

Industrial yarn up to final product
– Solid state postcondensation
– Extruder and screws for high viscosity polymers
– Spinning systemsfor the specific polymer requirements
– Spinning beam suitable for 2,3,4,6,8 or 12 ends per position
– Machine layout and godet duos with draw and shrinkage ability up to 13,200 dtex (super coarse
denier yarns)
– Machine layout for all industrial yarn processes such as HM, LS, SLS, HMLS and airbags
– Twisting/cabling, beaming, weaving or knitting
– Dipping or coating
– Final products:
− Coated fabrics
− Geo-textiles
− MRG (Mechanical Rubber Goods)
− Tires

Conclusion
Oerlikon Barmag is traditionally the leading machine manufacturer within the manmade fiber industry, and,
moreover, an experienced provider of total solutions.

Oerlikon Barmag understands the requirements of practical applications. It offers complete solutions for
direct and extrusion spinning plants, providing process expertise and performance guarantees based on
the experience and the results of its R&D center, and the performance of existing machines and projects.
Supported by its own laboratory and testing facilities, Oerlikon Barmag is well equipped to devise viable
solutions for its customers.

Textile Technology – Issue 8 23

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
www.oerlikontextile.com
info.barmag@oerlikon.com