Solutions for FDY manufacturing - Oerlikon Barmag - Oerlikon Textile

Solutions for FDY 

manufacturing

As creative as the market 

Oerlikon Barmag, a division of 

Oerlikon Textile GmbH & Co. KG 

with sites in Remscheid, Chemnitz, 

Wuxi and Suzhou (both 

People’s Republic of China), was 

founded as Barmag AG in 1922. 

The company is the world market leader 

for spinning systems and equipment 

for manmade fibers, such as polyester, 

nylon and polypropylene, and texturing 

machines and – as a service provider – 

offers engineering solutions for the 

entire textile value added chain. 

High-tech from the market leader 

Its core competencies also include the 

production of the associated components 

for manufacturing manmade 

fibers, such as extruders, winders, 

pumps and godets. As a future-oriented 

company Oerlikon Barmag’s research 

2 FDY solutions – Oerlikon Barmag 

and development is driven by the idea 

of energy-efficiency and sustainable 

technologies. With the expansion of the 

product range to include polycondensation 

systems and their key components, 

the company now caters to the 

entire process – from the monomer all 

the way through to the textured yarn. 

At your service 

The primary Oerlikon Barmag markets 

are Asia, and China and India in 

particular, as well as the Middle East 

and Europe. Correspondingly, the 

company – with its approximately 

1,700 employees – has a worldwide 

presence in 120 countries as part of 

the Oerlikon Textile network of production, 

sales and distribution and service 

organizations. At the Oerlikon Barmag 

R&D Center – the largest of its kind in 

the world – within the company’s head- 

quarters in Remscheid, highly-qualified 

engineers and technicians develop 

innovative and technologically-leading 

products for tomorrow’s world. 

Oerlikon Barmag machines and components 

rely on a large number of 

registered trademarks and international 

patents.

Table of contents 

Plant engineering 4 

FDY spinning solutions 6 

e-save – energy saving and more 10 

Process solutions 12 

Key components 20 

Extrusion equipment 22 

Pumps in a spinning plant 24 

Mixing and metering 26 

Spinning head series SP8 x 28 

Spin packs 29 

Quenching systems 30 

WINGS 32 

Godets 34 

ACW 36 

i-QOON 38 

Plant Operation Center (POC) 40 

SUN – Service UNlimited 42 

FDY solutions – Oerlikon Barmag 

3

Plant engineering 

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 Textile’s strong global 

network form a solid basis and the perfect prerequisites for Oerlikon Barmag as a solutions provider. 

Many texturizers depend on the import of POY which means 

that they have little influence on delivery times or on yarn 

quality. Having your own spinning equipment, however, 

opens up the opportunity to produce yarn independent of 

POY deliveries and to determine and control the yarn quality. 

Thus, it is possible to quickly and flexibly react to changes in 

the market. 

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. 

In plant engineering and construction, the term plant design 

means turnkey construction. This means that starting from 

the feasibility study through to the implementation of projects, 

the customer will receive all services from a single source. 


Oerlikon Barmag plant engineering delivers the following 

services: 

- feasibility study 

- consulting services 

- engineering services 

- basic and detailed engineering 

- guarantees for product and production 

Examples for engineering services are: 

- project management 

- plant layout and process engineering 

- machinery engineering 

- electrical and instrumentation engineering 

- piping engineering 

- polycondensation 

Oerlikon Barmag plant engineering looks after the complete 

processes, from the CP to the DTY machine, and includes 

chip handling, auxiliary plants, utility plants, general electrics 

as well as the respective documentation.

A selection of reference projects 

Engineering is one of the three supporting columns 

of Oerlikon Barmag’s solutions philosophy. In com- 

bination with cutting-edge technology and a comprehensive 

global service offering, engineering 

meets customer demand for an overall solution 

from a single source. 

A choice of projects demonstrates our expertise in 

the challenging field of plant engineering. 

Project: The project covers a complete polyester plant from 

polycondensation up to monitoring the textured yarn. The 

polycondensation has a capacity of 100,000 tons per year 

and produces currently 100 tons a day of FDY. The spinning 

section consists of 4 lines with 24 positions at 24-end. For 

winding the yarn producer relies on the i-QOON twin winder, 

which offers an operation speed of up to 5,500 m/minute. 

Location: India 

Start up: March 2010 

Scope of supply: 

- Polycondensation 

- Transferline from polycondensation to spinning 

- Extruder, spinning, take up 

Engineering & construction: 

- Basic engineering 

- Detail engineering 

- Supervision of erection, commissioning and start up 

- Project management 

- Site management 

Project: Solution for coloured PET textile yarn with 

guarantees 

Location: Turkey 

Plant type: 14 Positions, 8-end PET FDY extrusion 

spinning plant, with yarn process guarantee 

Start up: August 2008 


- Chips conveying, storage 

- Chips crystallization, drying 

- MB chips drying, metering 

- Extruder, spinning, take up and accessories such as 

godet exhaust system. 




- Supervision of erection & start up 

Project: Solution for PET FDY with guarantees 

Location: Morocco 

Plant type: spun-dyed PET-FDY spinning and winding, 

6 Pos. with 8 ends 

Start up: January 2008 


- Plant operation center (POC) 

- Chips feeding, crystallizing, drying & distribution 

- Masterbatch-chips conveying, drying and metering 

- Extruder, spinning with continuous polymer filter, take up 

- Advanced side-stream injection (FLUMIX) 

- Spinning accessories such as spinneret preheating and 

cleaning system, spin-finish mixing and handling 

- Quench and take up air conditioning units 




- Process and product guarantees 

- Supervision of erection & start up 


5

FDY spinning with WINGS 

Higher, faster, further – this is more applicable to the FDY 

process than to any other textile spinning process. A 

continual increase in systems productivity has been noticeable 

with rises in the number of yarn ends, from originally 

2 or 4 ends to currently up to 32 ends per position. 

Yarn manufacturers – whether providers of standard qualities 

or niche products – are faced with increasing pressure on 

efficiency. In demand are methods and means that increase 

the performance, quality and efficiency of the production 

process. This is the starting point for WINGS. 

The WINGS concept 

Meanwhile standard for the POY process, WINGS proves 

that the concept has also mastered the FDY process. 

Developed with the objective of increasing the productivity 

and efficiency of FDY systems, the revolutionary concept 

bears the solution in its very name: Winding INtegrated 

Godet Solution – in short WINGS. The winder as a complete 

take-up machine removes the spatial separation of godets 

and winders common today. 

FDY requires hot godets during the spinning process. Here, 

the WINGS concept – which successfully revolutionized the 

POY process – scores even higher. 

Sustainable yarn production 

With its multistage energy concept, WINGS FDY offers 

numerous benefits. First, the new process layout reveals its 

potential: while the WINGS FDY requires a mere 6 kW for a 

single godet, a conventional system configuration needs up 

to 4 kW for each individual heating zone – in other words, 

four times as much! 

A further aspect of sustainability is keeping any generated 

and costly energy within the system. With regards to the 

WINGS FDY, this means systematically keeping “hot” and 

“cold” areas separated within the FDY process. 

However, WINGS goes even further. The water-cooling 

system removes energy from the system without 

burdening the air-conditioning unit. Hence, it is possible 

that the air-conditioning system can be smaller and more 

efficient in design. 

6 FDY solutions – Oerlikon Barmag


7

Conventional FDY spinning 

Our customers’ productivity goals and market needs motivate our 

solutions. We provide the spinning machine that is just right for the 

specific market requirements for the production of high-quality FDY 

yarns made from PET, PA 6, PA 6.6, PP and others. 

In general, gentle yarn treatment starting 

in spinning and further down at the 

take-up position results in a good yarn 

quality. Fewer yarn breaks mean a 

very efficient production, especially for 

multi-end spinning with 24 or more 

ends. 

Highly efficient FDY production 

with i-QOON 

Efficiency for yarn manufacturers is 

decisive in securing profit margins, 

particularly in the case of commodity 

yarns. Daily outputs of up to 600 

tons require mature solutions – which 

ensure that a high performance does 

not come at the cost of quality. Correspondingly 

in demand are systems 

with multi-filament spinning and 

take-up plants, particularly in polyester 

FDY production. You will be perfectly 

prepared for this with our FDY systems, 

which produce up to 24 thread 

lines on a single spinning position. The 

core of these systems is the i-QOON 

twin winder, which offers an operation 

speed of up to 5,500 m/minute. 

Our machine layout ensures the lowest 

conversion cost per produced ton of 

yarn. The simple operation, low waste 

ratios and low energy costs underline 

the performance and efficiency of our 

FDY solutions. 

Spinning of sensitive materials 

with ACW 

Different materials require different 

technologies. To this end, polyamide is 

currently manufactured using spinning 

systems comprising 8 to 16 ends. And 

the Oerlikon Barmag program offers 

proven components for this. 


For these FDY processes, the ACW 

winder is available. In addition to high 

winding speeds, the top-quality packages 

offer yarn manufacturers decisive 

profit margins. 

High count yarn and microfilament 

yarn 

The production of high count (>100 filaments) 

yarn has special requirements 

for the spinning and take-up area. We 

support you with a wide range of spinning 

and quench systems applicable 

to different types of high count yarns. 

EvoQuench is the key for production 

success. All components from spinning 

down to the winder are chosen to 

assure excellent yarn qualities. 

Control concept 

Generally, the drive concept of our FDY 

lines consists of individual inverters, 

which increase the system’s flexibility. 

The systematically applied “plug and 

work” design concept creates the ideal 

prerequisites for fast system installation 

and commissioning. 

The kinetic buffering system perfectly 

protects the system against short-term 

power outages. Yarn cuts, and hence 

unnecessary yarn waste, are avoided. 

The Profibus standard ensures that 

the FDY spinning system is universally 

expandable. The electrical design 

ensures electromagnetic compatibility. 

Energy efficient components 

Future-oriented technologies are 

energy-efficient. Our systems have 

been designed in accordance with this. 

e-save-certified components – 

such as our HF-technology godets – 

help you to maximize profits. The 

Central DC bus ensures an improved 

energy balance within the system and 

hence helps save on electricity costs. 

POC (Plant Operation Center) 

Simple, user-friendly operation via 

the graphic interface of a PC display 

screen makes formulation management 

and data input of line and production 

parameters easier. A log function 

significantly simplifies service to the 

machine. Appropriate automation concepts 

- from process control to full 

bobbin and data tracking are available 

within the complete FDY product 

program.


9

e-save – energy saving and more 

Think e-save and reduce your production costs! 

Under this motto Oerlikon Barmag started promoting 

energy-conscious machines and components 

in 2005. The combination of high-performance 

machines and systems, high flexibility and low 

conversion costs is enabling manufacturers to be 

successful market players. 

The focus of e-save is on the reduction of the conversion 

costs. In 2005, Oerlikon Barmag developed and launched 

the e-save label, which is awarded to those components 

whose energy consumption has been significantly reduced 

compared to standard components available on the market. 

Demands and inquiries from our customers have encouraged 

us to systematically further research and develop the 

approaches we have already taken. Like a stone thrown into 

a lake, e-save is creating ever more positive repercussions. 

In addition to energy-efficient components, Oerlikon Barmag 

offers resource-minimizing solutions in many areas. 

Energy and environmental costs are also a considerable 

factor in FDY production systems. Today, they already cause 

up to half of the conversion costs of a spinning plant. All 

savings in this area benefit the local environment, while 

energy and resource efficiency are becoming ever more 

important locational factors on a global level. 


Energy prices will tend to go up in the future due to growing demand.

There are numerous possibilities for sustainably lowering the 

consumption of valuable resources. Firstly, there are energyoptimized 

components, for example Oerlikon Barmag’s SP8x 

spinning beam, which consumes more than 40% less energy 

than other more common designs. In a FDY spinning system 

with 144 positions, this generates an annual saving of 

approx. U$ 90,000. 

Reducing the consumption of process air is an important 

objective of the EvoQuench. Radial quenching consumes 

60-80% less air than cross-flow quenching – 

and can be used for manufacturing microfilaments and 

commodity yarns of up to 2 dpf (FDY). 

Multi-filament spinning saves energy 

However, the utilization of efficient components is only one 

step on the path to creating smart production processes. 

Restricting the examination to the spinning system alone 

does not take important factors into account. Within this 

context, the multi-filament capability should definitely be 

considered an energy-saving factor. Spinning 24 end FDY 

using a spinning beam with DIO spin packs and a quenching 

unit serving 24 threadlines is therefore considerably more 

efficient than two 12-end spinning positions. 

A decisive associated factor that influences the overall 

energy consumption is the air-conditioning system. Drives, 

heating systems, components that come into contact with 

the melt as well as the filaments radiate heat. If this heat 

radiation is reduced by means of excellent insulation, the 

air-conditioning system can be small, hence itself using less 

energy. 

Oerlikon Barmag – with its focus on innovation and 

technological leadership – provides a variety of machines, 

components and solutions that stand out through their 

excellent resource efficiency and thus easily fulfill the 

requirements defined by the e-save label. 

Savings potential by multi-end technology 

24 end FDY spinning compared to 2 x 12 end spinning 


11

Process solutions 


Our customers can benefi t from the comprehensive optimization 

of single processes along the textile value chain. Our big advantage 

is the fact that Oerlikon Textile serves the world’s largest 

spread of applications in the textile machinery industry. Oerlikon 

Barmag offers complete production lines from a single source – 

to offer the best possible solution – and we also work together 

with partners if special external expertise is necessary. 

Technology and support going hand in hand 

Innovative machines and systems are just part of the story. 

Oerlikon Barmag‘s process solutions turn machines into teams. 

They integrate production processes and match every item of 

equipment perfectly to the next. Customers profi t from Oerlikon 

Barmag’s comprehensive process know-how along the polycondensation, 

spinning and texturing steps in the textile value chain. 

Oerlikon Barmag’s solutions take a big weight off customers’ 

minds. Oerlikon Barmag’s one-stop shop covers everything from 

fi nance through to turn-key plants. Top machinery, comprehensive 

process skills, professional advice and service are all in the 

package.


13

Polyester 10 to 12 ends 

Flexible with a wide working window: this is 

the motto of our 10- to 12-thread lines systems 

for manufacturing polyester FDY. Microfilament 

yarns, trilobal products, spun-dyed filaments, high 

titers and particularly high package weights – the 

systems fulfill all these demands. 

All process-influencing system components, such as the 

spin-finish system, the migration nozzle, godet surfaces and 

the tangling unit, are precisely geared to each other, hence 

guaranteeing the very best yarn quality. 

The machines are equipped with the proven ACW winder. 

Downstream processing companies favor ACW packages 

particularly because of their excellent take-off performance. 

Many of the units used come with the e-save certificate. 

This means that these components are characterized by 

particularly low energy consumption. The SP8x spinning 

head stands out here with its improved thermal insulation. 

The HF godet heater focuses the heating energy on the 

godet jacket as this is the only part that needs to be heated. 


Process 

Final titer 30 - 500 den 

Single filament titer 0.3 - 4.2 dpf 

Filament count 12 - 288 

Ends per position 10, 12 

Mechanical speed 3,500 - 6,000 m/min 

Chuck length 1,380; 1,500 mm 

Extruder or direct spinning 

Spinning beam series SP8x 

Quenching systems SP82, EvoQuench 

Winder type series ACW 

Technical data are dependent on individual operation 

conditions. Not all values can be combined.


15

Polyester 24 ends 

Economical manufacturing of commodity yarns. 

This forms the basis of our 24-thread lines polyester 

FDY systems. Numerous details perfectly combined 

and tuned to each other ensure production 

success within a challenging market segment. 

Lost your thread? You won’t with us! An elaborate yarn guide 

guarantees record low string-up times. And the stable yarn 

path in our systems guarantees high full package yield. 

Using the i-QOON winder you can wind up 24 packages 

simultaneously. And you can also handle 24 yarn ends with 

the extensively automated string-up technology. 


Process 


Single filament titer 0,5 - 3.0 dpf 


Ends per position 24 


Chuck length 2 x 1,380 mm 

Extruder or direct spinning 


Quenching system SP82, EvoQuench 

Winder type series i-QOON 




17

Polyamide 6 and 6.6 

Polyamide yarns and the fabrics manufactured 

using them stand out as a result of numerous 

excellent properties. Deep dyeing at low temperature, 

a soft and pleasant fabric handle and also 

elasticity (high elastic recovery) are just a few of 

these properties. 

Particularly the high elasticity places huge demands on the 

system configuration: using a fifth godet positioned upstream 

to the winder achieves a considerably better package build 

vis-à-vis conventional systems. This is especially beneficial 

when manufacturing microfilament yarns and exceptionally 

fine titers. 

Needless to say, the polyamide flat yarn systems also draw 

on units that have proven themselves in the polyester 

production process, such as HF6 godets and ACW winders. 

Therefore, the system offers a broad titer range, simple 

handling, reliable components and excellent yarn quality. 


Process PA 6 




Ends per position 10, 12, 16 


Chuck length 1,500; 1,600 mm 

Extruder spinning 


Quenching systems SP82 

Winder type series ACWW 

Process PA 6.6 




Ends per position 10 


Chuck length 1,500 mm 

Extruder spinning 

Spinning beam series SP8x, SP4x 

Quenching systems SP82 

Winder type series ACWW 




19

Key components 


First-class solutions comprise fi rst-class machine systems manufactured 

using fi rst class components. This commitment determines 

the quality of our components. 

Oerlikon Barmag’s product range comprises extruders all the way 

through to the winding systems for all components within a spinning 

plant. As a systems constructor, we know the importance of 

the individual process steps and each partial component. 

For this reason, all Oerlikon Barmag components have their own 

success story: we have been designing and constructing extruders 

since 1958, the company has more than 80 years of experience 

in building pumps and has supplied in excess of 100,000 

winders throughout the world since 1972. 

We are not content with merely tried-and-tested design – our mission 

statement is the continual further development of all components 

to achieve even greater effi ciency and even better technical 

solutions for our customers.


21

Extrusion equipment 

Oerlikon Barmag spinning extruders excel in gentle 

and homogeneous melt production and are noted for 

cost effectiveness, reliability, and long service life. 

The utilization of top-quality, low wear materials – in particular 

for the extruder cylinders and the extruder screws – ensure 

long-term, error-free operation. The screw geometries with 

special homogenizing components have been determined 

to ensure short dwell times, in order to keep the thermal and 

mechanical loads of the melt to a minimum – the basis for 

excellent melt and hence first-class yarn quality. 

Oerlikon Barmag extruders fulfill the energy saving requirements 

for e-save. The e-save label is given to systems and 

components that have energy consumptions significantly 

lower than standard equivalent systems and components 

available on the market. 

Oerlikon Barmag extruders are chracterised by a good 

barrel insulation resulting in energy savings and a low surface 

temperature on the barrel jacket. The two-step spur gear 

guarantees long service life and smooth running. The feed 

area for inert gas or vacuum is designed to prevent oxidation 

of the polymer, thus ensuring trouble free spinning. Specially 

matched screw and barrel materials result in good sliding 

properties and low wear. 

Throughput capacity 

24D 4E 6E 7E 9E 10E 12E 15E 17E 

PET max. kg/h 70 130 200 300 400 520 820 1,120 

PA6 max. kg/h 40 80 125 200 270 350 550 750 

PA6.6 max. kg/h 40 70 120 180 240 315 - - 

30D 4E 6E 7E 9E 10E 12E 15E 17E 

PET max. kg/h 90 160 260 380 500 660 1,000 1,380 

PA6 max. kg/h 45 90 145 230 310 400 630 - 

PA6.6 max. kg/h 45 90 140 200 280 380 - - 


Air-cooled extruder series 

These are the perfect choice for processing PET, PA6, PA6.6, 

PP and other spinning polymers in all viscosity ranges for all 

manmade fiber requirements. An output ranging from 3 kg/ 

hr to 1,500 kg/hr is possible. This extruder version includes 

a fine-graduated program with screw diameters from 30 to 

250 mm, and screw lengths of 30 L/D or 24 L/D. Further, the 

specifically-cooled barrel sections expand the production 

window. 

The additional feature offered for this series is the control 

cabinet, which is integrated into the extruder frame. This version 

transforms our well-established model into a compact 

unit with significantly less wiring. 

All versions are available with or without a cooling system for 

the barrel. An injection system introducing master-batches 

or liquids into the polymer stream at various locations for 

customized fiber characteristics is also available.


23

Pumps in a spinning plant 

Booster pumps 

Booster pumps build up the pressure which is required by 

the system – with a high degree of flexibility and reliability. 

Booster pumps in polymerization or polycondensation 

plants, also known as transfer pumps, receive the necessary 

supply pressure from the discharge pump. These are used 

to provide the necessary pressure for the downstream consumer 

units. These consumer units include spin pumps, flat 

nozzles, perforated plates for granulation, etc. Frequently, the 

conditions within the system can also change, for example, 

through standstill of the downstream units. These demand 

flexibility; depending on the application even negative differential 

pressures can occur. Oerlikon Barmag booster pumps 

solve these tasks thanks to the universally applicable design 

of the bearing lubrication system. 

Planetary melt spinning pumps 

The spinning pump is one of the key components of a 

spinning system. Even when used over many years of 

production, all Oerlikon Barmag spinning pumps guarantee 

consistent yarn quality, the most important factor in successful 

yarn production. 

The special advantages of Oerlikon Barmag’s planetary gear 

spinning pumps include: 

- optimal melt flow due to rheologically advantageous melt 

channels 

- melt channels with optimised surfaces, ensuring superior 

flow conditions 

- high-precision manufacturing methods, allowing for excellent 

running performance and stable melt exchange 

- specially designed relief grooves in the melt outlet area of 

the gears, for minimized compression forces and operation 

with few fluctuations in the flow. 

Together, these advantages translate into the uniformity of 

the melt streams. 


Planetary spin-finish pumps 

The more even the application of the spin-finish liquid to the 

yarn, the better the yarn quality. A trailblazing design now 

sets considerably higher standards in terms of feeding 

accuracy, reliability and durability. 

The planetary concept is based on the proven planetary 

gear pump principle with a centrally driven sun gear and four 

planetary gears in each level. With four outlets per level this 

design is very space saving. 

The balanced force ratio within the pump and the 

constructively influenced low bearing load guarantee low 

frictional wear. 

In addition to its small size with flow paths of equal length, 

one major benefit is the large number of possible outlets 

per pump, whereby the maximum number of outlets 

is 40. Hence, for a spinning plant with a take-up unit for 

20 threads, just one spin finish pump would suffice for a 

double spin finish system. This series is designed for use 

with all commercially available types of spin-finish, from high 

down to low oil concentration. 

PROFIN 

Feed accuracy, operating stability, and servics life of the 

equipment are the fundamental properties of our spin-finish 

pumps. As far as the PROFIN series is concerned, excellent 

feeding accuracy, optimum internal flow conditions and the 

self-venting effect which prevents the agglomeration of airbubbles 

represents preconditions for a precise and uniform 

oil-application on a high quality standard.


25

Mixing and metering systems 

More than 90% of the world’s textile polyester and 

nylon filaments are spun in raw white. Dying the 

yarns or textiles takes place later in the form of 

package or piece dyeing despite the fact that these 

processes are in many respects inefficient. 

The energy requirements for heating the dye bath and subsequent 

drying of the dye product – in the case of package 

dyeing, we must also consider the rewinding – are high. The 

high consumption of water and chemicals and the associated 

volume of contaminated waste water have a negative 

impact on the environment. Furthermore, the dyeing process 

is time-intensive. 

e-save with spin-dyeing 

An alternative is the spin-dyeing of textile and industrial 

yarns. As the masterbatch is directly added and mixed into 

to the polymer melt, no further process steps are required 

in the dye plant. The spin-dyeing requires only a fraction of 

the energy, the water, the processing time and the space 

needed for conventional dyeing processes. 

Additives and dyes for plastics are becoming an increasingly 

important part of the manufacturing process. The properties 

of the polymers can be extensively modified as a result of 

additives. The option of directly introducing these additives 

during the manufacturing process (e.g. fibers or films) provides 

a high degree of flexibility and increased efficiency. 

The dynamic, three-dimensional mixing principle has proven 

to be an excellent choice when feeding additives, dyes, 

stabilizers and other polymers. Pumps for liquid additives 

or compact combinations of injection extruders with gear 

pumps are used for feeding. The systems can be integrated 

in various areas of the melt system. 

Feed options 

Additives can be fed into the polymer at various points. The 

appropriate point must be determined, taking flexibility and 

costs for each process individually into consideration. 


Powered 3DD mixer 

One or more additive flows can be added to the main melt 

flow upstream to the mixer. The constant changing of the 

rotor/stator groove allocation creates a dynamic 3-dimensional 

flow that includes both a longitudinal, dispersive and 

distributive mixing result. 

Type Ø throughput 

(mm) kg/h* 

6E-3DD 60 160 

7E-3DD 75 260 

9E-3DD 90 380 

10E-3DD 105 500 

15E-3DD 150 1,000 

17E-3DD 175 1,400 

20E-3DD 200 1,800 

22E-3DD 225 2,300 

25E-3DD 250 2,800 

* textile PET 

Feed position Extruder hopper At 3DD mixer 

on the extruder 

Technical data powered 3DD mixer 

At powered 

3DD mixer 

form of additive granulate melt; liquid additive melt; liquid additive 

flexibility 0 0 + 

costs ++ + 0

Feed extruder with metering pumps 

These components are required whenever master batch 

melts need to be metered into the main melt fl ow under 

high pressure. Throughput volumes from 3 kg/h can be 

metered. 

3DD mixer as an extruder extension 

This mixing unit is attached to Oerlikon Barmag extruders as 

a screw and cylinder extension. The master batches to be 

added are either fed via the extruder hopper (granulate) or 

later into the mixing zone (melted up, liquid). The mixing zone 

can be separately heated or cooled. 

Powered 3DD mixer as a separate unit 

This unit is a hot melt extruder with a dynamic mixing function. 

Here, the pressure differential required for mixing is 

extensively compensated by the pressure build-up in the 

screw section. The speed can be selected in accordance 

with the mixing task. The melt temperature can be infl uenced 

by the air-cooled mixing cylinder. The mixer is designed for 

integration into melt distribution systems for larger throughput 

volumes (> 100 kg/h). Both melt and liquid mass fl ows 

can be fed in. 

Promix AC 

For customized feeding of additives or dyes (liquid) at the 

spinning position, this planetary gear pump offers an injection 

function. To this end, the dynamic mixer works synchronous 

to the pump speed. Pumps with 3, 4, 5, 6, 8, 10, 12 

or 16 outlets are available. 

Promix VS 

To be able to tend to the mixing and metering functions 

separately in terms of process, a unit with 2 separate drives 

for mixing and metering was developed. The unit can be 

integrated into spinning positions or upstream into the 

melt distribution system. 

Inject AC - metering system for liquid additives 

This system was developed for feeding liquid dyes and additives 

into plastic granulate (unpressurized) or polymer melt 

(pressurized). One metering pump is used for unpressurized 

feeding. 

When feeding under pressure, two metering pumps in series 

are used, whereby the fi rst pump carries out the pressure 

build-up and the second the high-precision metering. The 

speeds of both pumps are set using an intelligent control 

system. 

The system can be completed with pressurized tanks with 

electrical fi lling height monitoring and valves. Valve technology 

enables fast dye changes using a rinse mode. 


27

Spinning head series SP8x 

First-class spinning heads make first-class yarns make first-class 

profits! The quality of the thread is determined during spinning. 

The manifold in an Oerlikon Barmag spinning line is specially 

optimized regarding melt residence time, pressure drop and 

shear rate. It is characterized by: 

- flow-favorable melt distribution for excellent yarn uniformity 

along the spinning line; 

- high surface quality of the pipes ensures favorable melt 

flow behavior for superior quality right from the first day of 

production; 

- absolute dead spot-free design is a precondition for low 

break levels and high yields; 

- the overall distribution system is almost maintenance-free. 

Oerlikon Barmag’s spinning head series covers the processes 

for textile and industrial yarns as well as home 

textiles even for processing critical materials like PA6. In all 

cases the spinning head steam heating ensures excellent 

temperature uniformity. 

e-save with SP8x 

The Oerlikon Barmag SP8x spinning head concept unites 

the advantages of high-end melt quality. The design of the 

spinning head has considerably reduced the heat-radiating 

surface and simultaneously significantly improved the insulation. 

This has resulted in a more than 40% reduction in the 

heat-radiation in comparison to the predecessor SP5x system. 

In trials, this has revealed, for example, energy savings 

of more than 200,000 kWh/year for a 36-position system. 


The SP8x spinning head ensures economic spinning processes 

with high product quality through its very even melt 

guidance system with optimized residence time. Furthermore, 

the shroud – which can be specifically adapted to the 

respective product on request – ensures an extremely high 

level of flexibility. The shroud is part of the Dowtherm-heated 

spinning head and guarantees extremely high temperature 

evenness without the additional energy requirements of an 

electrically-heated concept. This system also enables the 

production of microfilaments without loss of quality and productivity 

and excellent productivity for standard titers. 

Needless to say, the well-known self-sealing Oerlikon 

Barmag spin packs can also be used for this system. The 

rheologically-optimized melt distribution and uniform heating 

ensures that the good melt quality in the spinning head is 

also continued within the spin pack. 

Reduced spacing with zig zag 

In combination with the EvoQuench radial inflow quenching 

unit in zigzag layout, the SP8x is also available in a zigzag 

design. The reduced spacing in comparison to a standard 

EvoQuench and SP8x spinning head allows for a higher 

number of spin packs or bigger packs in the same position 

pitch. This option is available for 88 and 104mm spin packs.

Spin packs 

Advanced spin pack 

Through continual further development of the spin packs, the 

spinneret surface has been increased by up to 25% while 

maintaining the same external dimensions. The throughput 

required for the spinning process can hence be achieved 

with a smaller spin pack diameter. The spinning head melt 

residence time reduces by 10%. 

The new design offers the following process benefits: 

- increased filament distance on spinneret for better filament 

cooling and fewer yarn breaks, especially for micro- 

fiber and high count; 

- large filter surface for higher throughput, compared to 

other spin packs with the same outer spin pack diameter; 

- large filter surface for longer spin pack operation time; 

- increased filament count (microfiber) compared to other 

spin packs. 

The advanced spin pack is available as the proven self sealing 

version, however, for the production of polyamide 6.6 

we supply a forced sealing version. 

Double-in-one 

When looking at throughput, FDY systems for small titers 

require a relatively high level of investment. The 24 and 

32-fold Double-in-one (DIO) spinning plant concept has 

been able to considerably reduce the investment costs 

while maintaining yarn quality. 

The DIO concept, with two completely-independent spinnerets 

in one base, allows manufacturers to use approx. 

30% less space vis-à-vis single packages while retaining 

the titer evenness. Microfilaments with 24 ends can be 

efficiently manufactured if the DIO technology is combined 

with the EvoQuench system. 


29

Quenching systems 

The main task of the quenching system within the context of complex spinning processes is the even 

quenching of the liquid filaments at the exit of the spinneret. Oerlikon Barmag quenching systems 

supply a uniform, turbulence-free airflow for achieving excellent uster values. 

During the quenching process, each filament is supplied 

with the same amount of cooling air, hence ensuring defined 

crystallization and orientation of the polymer molecules which 

is the basis for optimal uster, elongation and dyeability. For 

this reason, the quenching process has a decisive influence 

in achieving excellent yarn qualities in the synthetic filament 

manufacturing process. Moreover, all current processes are 

covered by this system e.g. PET, PA 6, PA 6.6, PP and others. 

Quenching systems: quality assurance also for 

microfiber yarns 

We provide different quenching systems especially designed 

for our customers’ needs: The standard cross-flow quench 

system is suited for standard yarns and microfiber yarns 

higher than 0.7 dpf (denier per filament). The cross-flow 

quench system with quench booster stabilizes the production 

of yarns in the 0.7 to 1 dpf range. 

For the production of PET high-count yarns and microfiber 

yarns, we recommend the EvoQuench system, which allows 

for either a 10 to 12 end machine with up to 288 filaments 

(and filament counts down to 0.3 dpf) or a 24 to 32 end 

machine with up to 144 filaments. 

The Windows-based GUIDE system controls the airflow. 

Various quench air profiles, depending on the process 

requirements, are available. 


Cross-flow quenching system – one unit for (almost) 

everything 

This quenching system is the number one choice for all 

commodity applications. Robust, easy to use, suitable 

for a broad range of titers and all standard polymers, the 

Oerlikon Barmag cross-flow quenching system feels at 

home in almost all FDY spinning processes. As a result of 

the specially constructed rectifier, which corresponds to all 

requirements in terms of even and laminar air, extremely 

high yarn qualities can be achieved. 

EvoQuench – something innovative from the 

technology leader 

In contrast to the cross-flow, the air here is symmetrically 

guided from the outside of the thread bundle to the inside. 

This ensures optimal cooling-air flow of the thread along the 

entire length of the yarn surface. The EvoQuench system 

was developed for microfiber yarns with low filament count, 

but also covers a good range of commodity yarns. With 

more than 3500 installed positions the EvoQuench system 

is on its way to becoming a sales hit made by Oerlikon 

Barmag. 

e-save with EvoQuench 

In the quenching unit, it is the consumption of controlledprocessed 

compressed air that is the criterion that determines 

the resource consumption and hence the conversion 

costs. Depending on the titer and dpf, Oerlikon Barmag’s 

EvoQuench unit reduces the air requirements by between 

70% and more than 80% compared to a cross-flow 

quenching unit. The air savings per spinning position add 

up to more than 20,000 m³ every year. 


31

On the WINGS of success 

WINGS FDY is the consistent application of the WINGS 

concept with its many benefits to the FDY process. The 

new FDY machine oversteps the limits of conventional 

FDY spinning systems in terms of optimised production 

processes, waste ratios and energy consumption. 


WIN - less energy consumption and less CO 2 

emissions 

Maintaining – or even reducing – conversion costs is a constant 

challenge for successful filament producers. 

WINGS FDY brings this objective tangibly close. The innovative 

FDY process consumes significantly less energy than 

conventional spinning-drawing systems. Oerlikon Barmag’s 

green WINGS FDY technology consumes approximately 

30 % less energy than conventional FDY solutions - and thus 

generates less CO 2 emissions.

Technical data 

Material 

speed 

max. 

[m / min.] 

denier range / 

yarn end 

den / final 

WIN - more productivity through waste reduction 

In today’s competitive environment, waste reduction is the 

ultimate challenge to sustain a profitable business. 

WINGS FDY streamlines and shortens the string up process 

by a revolutionary floor-operated machine layout. 

WIN - a better start-up performance 

From the conception of a project through to the installation 

of the machines, your customer anxiously awaits the delivery 

of the first filament yarn. 

WINGS simplifies and shortens the erection and start up 

process by means of extensive plug and play solutions and 

completely preassembled as well as tested units. 

WIN - a future-oriented and reliable FDY process 

WINGS FDY opens the door to the future. Using proven 

components, the innovative FDY process guarantees 

consistently-high yarn qualities, reduced conversion costs, 

a wide operating window and scalability for other thread 

counts. 

ends 

chuck length 

Polyester FDY 2,500 - 5,500 50 to 100 24 1,380 91 

Polyester FDY 3,500 - 5,500 50 to 75 32 1,600 76 

[mm] 

stroke length 

Technical data and limitations are in constant flux – as usual with new products that are still being brought to perfection. Thus for any questions or needs, please 

contact your personal sales contact. 

[mm] 


33

Godets 

Oerlikon Barmag godets are custom-developed components for manmade fiber production. Continual 

innovations in the areas of design, process and safety fulfill the ever-increasing demands of ever faster 

processes. Our godet families are renowned for their countless productive details. Their process 

technological properties make it possible to achieve outstanding results in a huge variety of processes. 

High productivity and competitiveness are ensured thanks to the following basic requirements: 

- Robust design; - Reduced maintenance times; 

- Achievable process speeds; - The suitable godets for all MMF processes. 

- Low operating cost; 

Godets for the FDY process 

For years, the HF godet series has been well-established in 

production facilities throughout the world and offers proven 

advantages. High-precision setting and control of heater 

temperatures with large godet working width, due to: 

- Inductive high-frequency heaters, based on the multi-zone 

principle, ensuring high efficiency and, therefore, minimum 

heat loss; 

- Individually controlled heating zones, each monitored by a 

temperature sensor. 

All HF godets have high godet shell wear-resistance. The 

shell and all other parts of our godets have a nickel surface, 

which is extremely corrosion-resistant, even in the case of 

aggressive media such as spin finishes and oligomers. The 

godet shell surface is available in ceramic or other coatings. 

The number of yarn ends per position have continuously 

increased from 8 to 12 to 24 ends. However, our godets 

achieve nearly the same yarn properties for all processes, 

regardless of the number of yarn ends. 

Lower energy consumption 

Compared to other godet heating concepts, the HF principle 

has 20% less power consumption than, for example, 50Hz 

heat pipe systems. The HF godet family thus easily fulfills the 

requirements for the e-save label. The energy savings are, 

independent of the increasing number of yarn ends per posi- 



tion, more than 1 kWh per godet. Lower energy consumption 

also reduces investment in a large-scale A/C system, 

power distribution units, etc. The power management 

ensures that the individual take-up positions are not required 

to provide maximum output. 

Digital control for user-guided operation 

All godet families are integrated in an interconnected control 

and drive system. The asynchronous motors are individually 

speed-controlled by digital frequency inverters with heated 

HF godets. The temperature control of the multi-zone heaters 

is also operated digitally. This guarantees an extremely 

easy, time-saving menu-controlled operation. 

Economic maintenance 

Extended maintenance cycles result in higher machine efficiency 

and increased productivity for the customer. Of special 

benefit are the easy machine assembly/disassembly with 

the aid of flange mountings, plug-in connections, as well as 

a decrease in the number of individual parts by 50%. This 

results in a significant reduction in maintenance costs. 

Dependable quality at high output rates 

Stable operation, even at the highest process speeds, is 

guaranteed by a fail-safe design principle and components 

that are uncompromising with regard to safety. This includes 

solid steel shells with no built-in parts as well as the drive 

motor and speed monitoring. 

Godets HFO250-535V60 HFO250-535V35 HFG220-400V60 HFG220-480V35 HFG220-545V35 

Speed [m/min] 400 - 6,000 400-3,500 350 - 6,000 350-3,500 350 - 3,500 

Diameter [mm] 250 250 220 220 220 

Length [mm] 535 535 400 480 545 

Max. temperature [°C] 160 110 200 110 110 

Lubrication Barolub Barolub Grease Grease Grease 

Draw force [N] 31 31 35 35 35


35

ACW 

The ACW – Advanced CRAFT Winder – represents the next generation 

of the successful CRAFT winder program. It incorporates many new 

features while retaining the essential characteristics and advantages 

of the preceding generation. 

Yarn quality 

Packages wound using the ACW are of better quality. The 

full package protection feature ensures lint-free packages. 

An improved take-off in further processing is guaranteed as a 

result of the possibility of varying the contact pressure along 

the entire length of the package. 

The hybrid bearing is designed for lifetime lubrication. 

Dispensing with oil mist lubrication ensures a more pleasant 

working environment for the operator: soiling of the 

machine, the yarn and the package are kept to a minimum. 

A sensor-controlled yarn catcher guarantees 100% uniformity 

for the transfer and the end locator. As a result of the 

electrically driven bailer rolls, the form of the packages can 

be influenced, hence enabling a qualitatively specified further 

processing. 

Efficient operating 

An extended parking time allows for more relaxed doffing, 

as the time window in which doffing has to be carried 

out has been considerably expanded. And the designers 

have also taken the operator into consideration in the 

development of the new ACW: the noise level has been 

significantly reduced with the birotor traverse motion unit. 

The service interface, positioned on the front of the winder, 

has noticeably increased the maintenance-friendliness for 


Winders for polyester processing 


service staff. The semi-automatic string-up device simplifies 

the string-up process for the operator, hence improving 

efficiency. 

Cost advantages 

Electrical chuck brakes offer yarn manufacturers various 

advantages: reduced energy consumption and non-wear 

– and hence maintenance-free – brakes. Soiling of the final 

products caused by brake dust is now a thing of the past. 

Design 

Smooth surfaces and the carefully considered layout of the 

components ensure that the ACW is a maintenance-friendly, 

easy-to-clean unit. The positioning of the electronic control 

unit – conceived as a plug-in component – makes the ACW 

approx. 25% shorter than other standard winders. Furthermore, 

the position of the control unit means the ACW does 

not require air-conditioning behind the take-up head. 

Production optimization 

To optimize the production processes, the ACW has a 

unique first yarn break detection system for determining the 

precise position of the yarn break. This feature is unique 

because the signaling of yarn breaks in the millisecond range 

enables accurate error and process analysis. The measured 

data are transferred to the plant operation center (POC) for 

statistical evaluation. Hence, the POC reliably supports the 

continual optimization of the plant. 

Version speed denier range / tube package ends [x] stroke length [mm] 

chuck length / ends max. yarn end inner Ø max. Ø volume [dm 3 ] 

mm / [ ] [m / min.] den / final [mm] [mm] 

ACW-6T 1500/10 3,500-6,000 50-500 125 440 10 x 120 / 16.4 

ACW-5T 1380/12 3,500-5,500* 50-300 110 440 12 x 91 / 12.7 

Winders for polyamide processing 




ACWW-5T 1500/10 3,500-5,500 12-210 125 440 10 x 120 / 16.4 

ACWW-5T 1500/12 3,500-5,500 12-100 125 440 12 x 97 / 13.3 

ACWW-5T 1600/16 3,500-5,500 12-70 125 440 16 x 76 / 10.4 

* 5,500 m/min. possible with a package of up to 420 mm Ø


37

i-QOON 

The i-QOON concept combines principally two winders in a single 

unit, with a total of 4 chucks. 

The winder is equipped with 1,380 mm long chucks, which achieve stroke lengths 

of 91 mm. The i-QOON winds up its packages with a maximum speed of up to 

5,500* m/min.The specification of these winders is perfectly suited for FDY processes 

(high-speed). 

The birotor traverse systems known from the CW and ACW winder series, and 

which have been sold more than 42,000 times, have been improved for the 

i-QOON winder. 

Double the solution 

The i-QOON has been designed for maximum output. Up to 24 packages can be 

wound simultaneously with the twin winder. Simply double the solution! 





i-QOON-5B 1380/24 3,500-5,500* 20-100 110 440 24 x 91 / 12.7 

* 5,500 m/min. possible with a package of up to 420 mm Ø 



39

Plant Operation Center (POC) 

POC – Plant Operation Center – is the all-embracing workflow management 

system from Oerlikon Textile. It is designed to detect and optimize the production 

processes within a production stage, e.g. spinning or over all production 

stages – starting with the raw material all the way through to the end 

product. 

Today, companies are confronted with challenges on all fronts: market requirements 

are becoming increasingly difficult to plan, pressure on margins is growing 

and the production environments of dynamic companies are becoming ever more 

complex. Within companies, data transparency, integrated processes and efficient 

resources planning are becoming success factors. 

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 ideal tools to further increase the productivity and efficiency of your 

systems. The software is modular, allowing you to create a customized system 

from the POC modules that is tailored to your precise requirements and that can 

be expanded at any time. 

With the available modules: Job disposition, Job View and Job Reports, the 

POC System functionalities can be expanded to establish the perfect link between 

the Plant Operation Center (POC) and the ERP (Enterprise Resource Planning) 

systems of the textile industry. With this technology, the POC really goes MES and 

is upgraded to a fully-functional Manufacturing Execution System. 


The POC creates transparency – the “Job Reports” 

module 

The status of manufacturing jobs is graphically displayed per 

spinning machine and/or per spinning position at all times. 

The screen shows comparable data of both current and 

completed jobs. The data is updated with each doff and is, 

therefore, extremely precise. 

The POC simplifies the workflow – the “Recipe 

Management” module 

Recipes define what will be produced. They include the complete 

list of all set-points or parameters that are important for 

the product. During production planning, recipes are distributed 

to the production units. 

The POC increases efficiency – KPI (Key Performance 

Indicator) in a nutshell 

The latest addition to the POC gives users the comforting 

feeling of being informed at all times and in all places. Highlycondensed 

information on the production systems can be 

accessed on mobile devices using apps. 


41

SUN - Service Unlimited 

Getting you to the top 

What are your expectations when you are deciding on new 

product ranges and equipment for your textile business? 

Do you really want to have several providers to manage the 

complex manufacturing processes you need to control? And 

can you risk facing the situation that after a few years your 

investment may be virtually worthless? 

We at Oerlikon Textile are convinced that you shouldn‘t 

accept any of these limitations. This is the reason why 

Oerlikon Textile has devised SUN – Service UNlimited – the 

new service initiative that our Customer Support offers with 

its brands Oerlikon Barmag, Oerlikon Neumag, Oerlikon 

Schlafhorst and Oerlikon Saurer to all its clients who require 

more than just service. SUN is a bundle of differentiated 

services that add real value to your Oerlikon Textile hardware 

and your daily business in a flexible way. 

Partnering for performance 

Oerlikon Barmag Service offers you a broad range of products 

and services to achieve your objectives - faster return 

on investment, shorter downtimes and process support. 

Based in Remscheid, a pool of highly qualified employees 

equipped to react fast and efficiently to the most varied 

customer demands. From erection and start-up to process 

consulting – our team of experts is waiting to support you. 

Moreover, in line with “think globally, act locally”, our worldwide 

network of service stations will always reach you – 

wherever you are. Local repair shops and on-site workshops 

at your production plant are characteristic of our service 

philosophy. 

Our R&D center at Oerlikon Barmag’s headquarters in 

Remscheid is equipped with ten modules forming closed, 

self-sufficient units with a total of ten spinning plants on various 

levels. All modules can be independently-operated in 

accordance with the respective process requirements. The 

texturing R&D center at Oerlikon Barmag’s texturing equipment 

hub in Suzhou provides all currently available Oerlikon 

Barmag draw-texturing machine types as well as facilities to 

evaluate process and machine performance supported by 

our experienced team of engineers. At both locations, customers 

can test their raw materials and products or develop 

new applications under optimum overall conditions. 

www.myoerlikon.com – access to success 

The myOerlikon customer portal is up to date at all times, 

24 hours a day and throughout the year. The customer portal 

has a clearly arranged and uniform website covering all busi- 


• Main Oerlikon Textile Service 

Network Stations plus more 

than 120 agencies worldwide 

ness units and their respective product lines. Our customers 

have online access to the latest documentation, tailored to 

their specific machines. 

The troubleshooting manual permits quicker and more efficient 

alleviation of problems via direct links. The SECOS 

e-Commerce system, well-known worldwide, is completely 

integrated. The Engineering tool supports and accompanies 

the entire engineering process from the concept to the 

turn-key plant. Innovative ideas and new solutions are added 

continuously. The latest encryption technology guarantees 

the maximum data security at all times.


43

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 

Oerlikon Textile Inc. 

8801 South Boulevard 

P.O. Box 70 46 

Charlotte N.C. 28241 

U.S.A. 

Phone +1 704 910 42 68 

Fax +1 704 910 42 09 

info.charlotte@oerlikon.com 

The information supplied in this 

brochure is for guidance only. 

We reserve the right to modify it 

at any time. 

OBA 206 e / 3/2012 

Studio 45 

Subject to changes 

Oerlikon Textile Far East Ltd. 

Room 2806 

China Resources Building 

26 Harbour Road, 28 / F. 

Wanchai, HONG KONG 

P.R.CHINA 

Phone +852 28 27 43 14 

Fax +852 28 27 52 50 

info.textile.hk@oerlikon.com 

Oerlikon Textile India Pvt. Ltd 

Empire Industries Complex 

414, Senapati Bapat Marg 

Lower Parel (West) 

Mumbai-400013 

INDIA 

Phone +91 22 6652 7900 

Fax +91 22 6652 7901 

management.bom@oerlikon.com

Solutions for FDY manufacturing - Oerlikon Barmag - Oerlikon Textile

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