eAFK - Oerlikon Barmag - Oerlikon Textile
eAFK - Oerlikon Barmag - Oerlikon Textile
eAFK - Oerlikon Barmag - Oerlikon Textile
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<strong>eAFK</strong><br />
Solutions for automatic<br />
draw textured yarn<br />
production
As creative as the market<br />
As creative as the market<br />
<strong>Oerlikon</strong> <strong>Barmag</strong>, a division of<br />
<strong>Oerlikon</strong> <strong>Textile</strong> GmbH & Co.<br />
KG with sites in Remscheid,<br />
Chemnitz, Wuxi and Suzhou<br />
(both People’s Republic of<br />
China), was founded as <strong>Barmag</strong><br />
AG in 1922.<br />
The company is the world market<br />
leader for spinning systems and<br />
equipment for manmade fi bers, such<br />
as polyester, nylon and polypropylene,<br />
and texturing machines and – as a<br />
service provider – offers engineering<br />
solutions for the entire textile value<br />
added chain.<br />
High-tech from the market leader<br />
Its core competencies also include<br />
the production of the associated<br />
components for manufacturing<br />
manmade fi bers, such as extruders,<br />
winders, pumps and godets. As a<br />
future oriented company <strong>Oerlikon</strong><br />
2 <strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
<strong>Barmag</strong>’s research and<br />
development is driven by the idea<br />
of energy-effi ciency and sustainable<br />
technologies. With the expansion<br />
of the product range to include<br />
polycondensation systems and their<br />
key components, the company now<br />
caters to the entire process – from the<br />
monomer all the way through to the<br />
textured yarn.<br />
At your service<br />
The primary <strong>Oerlikon</strong> <strong>Barmag</strong> markets<br />
are Asia, and China and India in<br />
particular, as well as the Middle East<br />
and Europe. Correspondingly, the<br />
company – with its approximately<br />
1,600 employees – has a worldwide<br />
presence in 120 countries as part<br />
of the <strong>Oerlikon</strong> <strong>Textile</strong> network of<br />
production, sales and distribution<br />
and service organizations. At the<br />
<strong>Oerlikon</strong> <strong>Barmag</strong> R&D Center – the<br />
largest of its kind in the world – within<br />
the company’s headquarters in<br />
Remscheid, highly-qualifi ed engineers<br />
and technicians develop innovative and<br />
technologically-leading products for<br />
tomorrow’s world.<br />
<strong>Oerlikon</strong> <strong>Barmag</strong> machines and<br />
components rely on a large number of<br />
registered trademarks and international<br />
patents.
Table of contents<br />
<strong>eAFK</strong> 4<br />
Feed systems 6<br />
Draw and texturing zone 7<br />
Heater / Cooling combinations 7<br />
Heater solutions 8<br />
Cooling combinations 10<br />
Twist insertion 12<br />
Quality management system 13<br />
Intermingling 14<br />
Take up zone 15<br />
Oiling solutions 15<br />
Take up solutions 16<br />
Cross sections 18<br />
<strong>eAFK</strong> standard<br />
<strong>eAFK</strong> coolfl ex<br />
<strong>eAFK</strong> Multispindle<br />
<strong>eAFK</strong> HTI<br />
<strong>eAFK</strong> HTI coolfl ex 1.0/1.2 active<br />
<strong>eAFK</strong> HTI coolfl ex 1.0/0.8 active<br />
Plant Operation Center 24<br />
Upstream processes 25<br />
SUN – Service Unlimited 26<br />
<strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
3
<strong>eAFK</strong><br />
Automatic texturing. Redefi ned.<br />
Having delivered more than 1,000 automatic texturing machines,<br />
<strong>Oerlikon</strong> <strong>Barmag</strong> is the world’s leading and most sought after automatic<br />
texturing machine manufacturer. The automatic AFK and AFK2 as<br />
well as the single section automatic texturing machine MPS are past<br />
milestones of <strong>Oerlikon</strong> <strong>Barmag</strong>, each generation bringing a quantum<br />
leap in texturing. Reliability, effi ciency, userfriendliness and the most<br />
economical production of high-quality yarns are the basic criteria<br />
<strong>Oerlikon</strong> <strong>Barmag</strong> texturing machines must fulfi ll.<br />
Well aware of the roots of success for an automatic texturing machine,<br />
honoring tradition while focusing on future texturing processes, <strong>Oerlikon</strong><br />
<strong>Barmag</strong> introduces the automatic draw texturing machine <strong>eAFK</strong>.<br />
Automatic texturing redefi ned.<br />
Market oriented<br />
Manufacturing of draw textured yarns was for nearly a decade characterized by<br />
manual processes. With changing manufacturing conditions in main production<br />
areas the process requirements have changed as well and automatic machines<br />
reappear in focus. The <strong>eAFK</strong> draw texturing machine is <strong>Oerlikon</strong> <strong>Barmag</strong>’s next<br />
generation automatic draw texturing machine, redefi ning what made <strong>Oerlikon</strong><br />
<strong>Barmag</strong> automatic draw texturing machines famous:<br />
economy reduced manufacturing costs with highest doffi ng<br />
effi ciency, less wear and spare parts and potentially higher<br />
process speeds through innovative cross sections<br />
effi ciency improved machine effi ciency with less downtime through<br />
reliable doff operation, automation interface and simplifi ed<br />
maintenance and operation<br />
excellence best package formation with future oriented ATT package<br />
build technology<br />
ergonomics operator friendly machine handling<br />
energy saving godet feed system, innovative drive systems and heater<br />
designs allow potentially reduced energy consumption<br />
enhancement improved yarn quality and process stability for a wide<br />
range of products and polymers (PET/PA/PP/PLA/PTT),<br />
specially for demanding products<br />
evolution closely listening to the market, our machines improve and<br />
evolve with rising requirements<br />
4 <strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong>
Feed systems<br />
Godet feed unit<br />
The single driven godet feed unit as being used in G1, G2<br />
and G2x has been derived as a principle from POY spinning.<br />
It has been introduced by <strong>Oerlikon</strong> <strong>Barmag</strong> in DTY machines<br />
in 2003. Optimized for the DTY process, it quickly convinced<br />
where highest requirements for yarn processing were key.<br />
The stress-free yarn transport offers advantages for both<br />
sides of the product spectrum.<br />
When producing fi ne denier products with high number of<br />
fi laments, it ensures higher yarn quality and extended yarn<br />
evenness over time. Friction-intensive products such as full<br />
dull or spun dyed, that usually quickly wear down those<br />
components they are in contact with, are processed with<br />
greater effi ciency and at lower production costs. This is<br />
fi rstly due to non-existent slippage and secondly due to the<br />
godet itself, which makes additional yarn-guiding elements<br />
or wear-reducing components such as yarn displacement in<br />
the yarn path, superfl uous.<br />
Other general advantages of godets include higher<br />
consistency over process time and from position to position<br />
as well as potentially lower energy consumption. By using<br />
godets energy savings of up to 5% can be achieved.<br />
Energy<br />
consumption<br />
Yarn<br />
treatment<br />
Shaft feed unit<br />
The centrally driven shaft feed system at W3 fulfi lls all<br />
the basic requirements for processing even delicate<br />
products from all kind of polymers. Yarn feed takes place<br />
in conjunction with nip rollers or – if required – aprons. For<br />
easy handling and maintenance, nip rollers are equipped<br />
with intermediate stop as well as quick release.<br />
With selection of latest materials the lifetime of coats are<br />
improved, which<br />
– infl uences maintenance cycles positively<br />
– reduces down time<br />
– increases machine effi ciency<br />
The feed unit W3 is standardly equipped with a yarn<br />
displacement system to reduce wear on coats.<br />
Wear<br />
parts<br />
Products<br />
Polymers<br />
Godet + ++ ++ + +<br />
Process<br />
fl exibility
Draw and texturing zone<br />
Pneumatic String up solution<br />
In order to string-up the machine, proper placement of the yarn in the heater and cooling are of<br />
importance. As standard, <strong>Oerlikon</strong> <strong>Barmag</strong> offers the <strong>eAFK</strong> with pneumatic string-up equipped with<br />
quick release function swivel arms that allow easy push in & out of twist stop rollers and yarn guides.<br />
The pneumatic string-up solution uses compressed air to move the function swivel arm into the top<br />
position by deploying a magnetic sledge, which also secures the positioning when in place. Easy<br />
operation by push buttons on each string up position make the pneumatic string up as operatorfriendly<br />
and process secure as possible.<br />
Heater / Cooling combinations<br />
Defi ning the right heater/cooling combination for a certain production range is the best option for<br />
optimizing production. There are technological and physical limits to be considered.<br />
Technological limits depending on yarn product are:<br />
• Surging<br />
• Yarn tension<br />
• Desired yarn quality<br />
Physical limits depending on yarn product are:<br />
• Heat transfer of heating system<br />
• Heat transfer of cooling system<br />
• Friction<br />
Depending on product titer and number of fi laments, the choice of heating in conjunction with cooling<br />
components can either improve the yarn quality or optimize the process speed – or even both. A<br />
further high-impact effect of choosing the right option is the potential energy saving. Apart from<br />
optimizing the production, the energy saving reduces the total manufacturing cost, depending on the<br />
choice of heater. In today’s demanding market, production optimization can be the difference between<br />
making profi t or a loss.<br />
<strong>Oerlikon</strong> <strong>Barmag</strong>’s experience, technology, components and cross-sections provide our customers with<br />
the possibility of freely selecting the cross-section that allows ideal production, depending on product –<br />
lowcost manufacturing of high quality products with the greatest-possible process effi ciency – <strong>eAFK</strong>!<br />
<strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
7
Heating solutions<br />
First heater<br />
Dowtherm*<br />
Dowtherm contact heaters have been successfully used in<br />
<strong>Oerlikon</strong> <strong>Barmag</strong> machines for over 30 years now and are –<br />
even today – state-of-the-art technology, particularly for<br />
multi and microfi laments. Anti-wear nitrated surfaces, deep<br />
V profi le and special pinches for preventing yarn heat-outs<br />
result in high yarn cleanness, extremely even crimping and<br />
excellent dye uptake for the textured yarn.<br />
<strong>Oerlikon</strong> <strong>Barmag</strong> Dowtherm heaters are open close<br />
heaters for easier operation and maintenance, equipped<br />
with manually closing doors. They are available in various<br />
lengths suitable for processing different ranges of products.<br />
Depending on the product portfolio customers can optimize<br />
their production with the right selection and combination<br />
of heater and cooling component. The correct selection of<br />
these components can infl uence<br />
– production speed and capacity<br />
– energy consumption<br />
– yarn quality<br />
*Dowtherm is a trademark of Dow Chemical<br />
8 <strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
HTI<br />
The HTI high-temperature heater makes it possible to<br />
achieve high speeds coupled with excellent yarn qualities<br />
due to stable yarn path and uniform heat transfer. The 1 m<br />
long heater consists of two heating zones that, equipped<br />
with special exchangeable inserts – developed and patented<br />
by <strong>Oerlikon</strong> <strong>Barmag</strong> – enable fast and simple replacement<br />
during standard maintenance work.<br />
This increases overall machine effi ciency by minimizing idle<br />
machine time resulting from maintenance and cleaning. The<br />
inserts are cleaned outside the machine, hence eliminating<br />
the customary problems associated with heater cleaning.<br />
Inserts are available for both heating zones, either with<br />
pinches or as full contact inserts. Different inserts can be<br />
combined for optimization of the process, catering to the<br />
special needs of highly critical products.<br />
Due to its design, the <strong>Oerlikon</strong> <strong>Barmag</strong> HTI heater has<br />
signifi cantly lower energy consumption in comparison to<br />
its Dowtherm cousin. This - combined with signifi cant<br />
potential process speed increase – makes the HTI heater is<br />
a worthwhile alternative investment consideration.
Heater<br />
Type<br />
Secondary set heater<br />
Dowtherm*<br />
Heater<br />
length<br />
Titer range<br />
den<br />
Preferred<br />
operational<br />
range<br />
Dowtherm set heaters with tubes generate evenlyset yarns<br />
and can be adapted in process by means of exchangeable<br />
tube inserts available in various designs – spiral pinched,<br />
half spiral pinched or fl at. Depending on process and<br />
product, the <strong>Oerlikon</strong> <strong>Barmag</strong>-developed solution allows<br />
yarn optimization in terms of loop-free yarns, a particularly<br />
important feature for multi- and microfi lament yarns.<br />
As standard, the heater is 1.30 m in height and available in<br />
standard and low-temperature versions for set treatment<br />
of highly-critical yarns. Secondary heaters are used for<br />
differential production on either side of the machine.<br />
Energy<br />
saving<br />
Yarn<br />
treatment<br />
Typically<br />
used for<br />
polymer<br />
HTI 1.0 m 30 – 300 30 – 300 ++ ++ PET, PP,<br />
PTT<br />
DTH 1.5 m 20 – 200 20 – 150 + + PET, PA,<br />
PP, PTT<br />
DTH 2.0 m 30 – 300 30 – 200 o o PET, PA,<br />
PP, PTT<br />
DTH 2.5 m 70 – 600 150 – 600 - - PET, PA,<br />
PP, PTT<br />
*Dowtherm is a trademark of Dow Chemical<br />
Typical application<br />
All kind of yarns<br />
depending on insert<br />
type and combination<br />
Fine yarn, micro and<br />
multifi lament<br />
Average commodities<br />
Coarse<br />
<strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
9
Cooling solutions<br />
Depending on product and process, the right combination of heating and cooling components is important<br />
for an optimized yarn production – crucial in today’s demanding markets. <strong>Oerlikon</strong> <strong>Barmag</strong> offers a variety of<br />
cooling components that are designed to work in harmony with our heater products.<br />
Plate<br />
Cooling plates have been developed by <strong>Oerlikon</strong> <strong>Barmag</strong> in line with the heaters. Respectively they offer the same process<br />
relevant features such as anti-wear nitrated surfaces, deep V profi le and special pinches for preventing yarn cool-outs.<br />
Cooling plates are available in various lengths to allow optimal heat transfer, depending on the product.<br />
Cooling<br />
length<br />
Titer range<br />
den<br />
10 <strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
Preferred<br />
operational<br />
range<br />
Yarn<br />
treatment<br />
Usually in<br />
combination<br />
with heater<br />
0.70 m 20 – 150 20 – 100 ++ 1.5 m DT*<br />
2.0 m DT*<br />
0.85 m 20 – 200 20 – 150 + 1.5 m DT*<br />
2.0 m DT*<br />
Typically used for<br />
polymer/den<br />
PA, PP, PTT<br />
20 – 70<br />
PA, PP, PTT<br />
20 – 100<br />
1.10 m 30 – 300 30 – 200 o 2.0 m DT* PET, PA, PP, PTT<br />
30 – 200<br />
1.75 m 30 – 300 30 – 300 - 2.0 m DT*<br />
1.0 m HTI*<br />
PET, PA, PP, PTT<br />
30 – 300<br />
Typical application<br />
Fine yarn, micro and<br />
multifi lament<br />
Fine yarn, micro and<br />
multifi lament<br />
Average commodities<br />
Fine yarn<br />
commodities<br />
2.10 m 100 – 600 150 – 600 -- 2.5 m DT* PET, PA, PP, PTT Coarse<br />
*DT = Dowtherm<br />
*HTI = High Temperature Insertion
Tube<br />
Cooling tubes have been developed by <strong>Oerlikon</strong> <strong>Barmag</strong> in response to rising requirements in downstream texturing<br />
in regard to process speed and friction. By using specially treated tubes <strong>Oerlikon</strong> <strong>Barmag</strong> developed cooling<br />
components that cover a wide range of products, eliminate cool-outs and offer improved process speeds due to<br />
reduced texturing zone length. The tubes are cooled by ambient air, but can also be connected to an air conditioning<br />
system to increase their cooling effect – so called active cooling – for an even wider range of applications.<br />
Cooling<br />
length<br />
Titer range<br />
den<br />
Preferred<br />
operational<br />
range<br />
Yarn treatment Usually in<br />
combination<br />
with heater<br />
0.80 m 20 – 300 20 – 200 ++ 1.5 m DT*<br />
1.0 m HTI*<br />
Typically used<br />
for polymer/<br />
den<br />
PET, PA, PP,<br />
PTT<br />
20 – 200<br />
1.20 m 30 – 600 70 – 300 O 1.0 m HTI* PET, PA, PP,<br />
PTT<br />
70 – 300<br />
Typical<br />
application<br />
Fine yarn, micro and<br />
multifi lament<br />
High speed<br />
Low friction<br />
Fine yarn, micro and<br />
multifi lament<br />
Commodities,<br />
High speed<br />
<strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
11
Twist insertion<br />
<strong>Oerlikon</strong> <strong>Barmag</strong> has apart from the early days of texturing machinery always focused on friction disc<br />
units as the most advantageous and fl exible form of twist insertion. Using different types of friction<br />
working discs as well as specially developed inlet and outlet discs the friction units can be adapted to<br />
any kind of product for optimal production.<br />
For <strong>eAFK</strong> the standard is the <strong>Oerlikon</strong> <strong>Barmag</strong> friction aggregate type 8E, which has been developed to fulfi ll the highest<br />
quality demands within the texturing process. Using synergies within the <strong>Oerlikon</strong> <strong>Textile</strong> group the open close friction<br />
aggregate FTS 53 has been mutually developed with <strong>Oerlikon</strong> <strong>Textile</strong> Components. Both friction aggregates share the<br />
same single driven housing, are interchangeable and as such provide customers additional fl exibility for optimization of<br />
process.<br />
Both texturing units have the following characteristics in common:<br />
•<br />
•<br />
•<br />
•<br />
•<br />
•<br />
•<br />
•<br />
•<br />
High fl exibility for a wide range of products – from fi ne 20 denier up to coarse denier of 600 den<br />
Designed for a maximum stacking of 10 discs with 9 mm thickness or 13 discs with 6 mm thickness<br />
Elastic and muffl ed high-speed bearings for extra low vibration at high speeds (up to 22,000 rpm)<br />
Low noise level<br />
Low variation of disc speed<br />
Lower energy consumption<br />
No displacement of texturing unit and entrance guide at S/Z switching<br />
Easy reversal of twist direction<br />
Easy removal of friction unit for maintenance purposes<br />
The individually driven type 8E texturing unit comprises<br />
a fi xed center design, which adds to the general<br />
characteristics, extraordinary sturdiness and lifetime<br />
evenness.<br />
12 <strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
The aggregate FTS 53 simplifi es string-up as a result of<br />
its open-close function. When placing the yarn into the<br />
aggregate, it can be single-handedly opened and closed<br />
once the yarn is secured in the center. Thus, it potentially<br />
improves string-up of very sensitive or complicated yarns.
Quality management system<br />
With rising quality requirements, the demand for online quality monitoring systems is also increasing.<br />
The target is not only monitoring the draw-texturing process, but also improving the overall process and<br />
increasing machine effi ciency. With <strong>Oerlikon</strong> <strong>Barmag</strong>’s online quality monitoring, products that do not<br />
meet set quality standards are easily identifi ed, withdrawn from the production process and replaced<br />
by yarn that meets the quality requirements. Hence, machine effi ciency is increased – valuable machine<br />
time is not used to process yarn that does not meet the required standards!<br />
Fibrevision Unitens<br />
The UNITENS concept in the latest generation of the unique<br />
combination of fl oating mean value, peak detection and CV<br />
evaluation, results in the highest standards in online yarn<br />
quality control, statistics, quality and plant management. As<br />
an integral part of the <strong>eAFK</strong>, UNITENS offers - in addition<br />
to the basic yarn quality evaluation and quality grading of<br />
the produced yarn - essential data for the highest doffi ng<br />
performance, the best machine service and maintenance, all<br />
resulting in the highest machine effi ciency and productivity.<br />
The sophisticated, but easy-to-handle UNITENS can be<br />
combined with <strong>Oerlikon</strong> <strong>Barmag</strong>’s Plant Operation Center<br />
(POC) software networking solution as well as with our<br />
CreelManager system.<br />
CreelManager<br />
The close link between UNITENS quality evaluation and<br />
<strong>Oerlikon</strong> <strong>Barmag</strong>’s CreelManager opens up – for the very<br />
fi rst time – the possibility of production and classifi cation<br />
of knot-free yarn packages, especially advantageous in<br />
conjunction with the automatic doffi ng function of the <strong>eAFK</strong>.<br />
The UNITENS system connected with the CreelManager<br />
represents a milestone in modern quality monitoring. The<br />
package quality information is considerably improved, which<br />
creates competitive advantages for manufacturers. With the<br />
help of special sensors in the creel, the UNITENS system is<br />
provided with information about supply package change.<br />
Hence, this information - with the knowledge about the<br />
supply package - can trace issues back as far as individual<br />
spinning positions, which for the fi rst time allows operators<br />
to monitor not only the performance of the DTY machine,<br />
but also of the prior production step in POY spinning. The<br />
objective of the system is to integrate the entire process<br />
chain into a total quality system (TQM).<br />
<strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
13
Intermingling<br />
Intermingling of yarn and there especially the number and regularity of the intermingling knots are one<br />
of the prerequisites for high end downstream operation. <strong>Oerlikon</strong> <strong>Barmag</strong> in close cooperation with<br />
world renowned brands for intermingling jets offers with the <strong>eAFK</strong> machine a wide range of intermingling<br />
possibilities throughout the process. Intermingling is an option that depending on downstream<br />
requirement has to be discussed.<br />
Pre-intermingling<br />
While processing fi ne denier and especially highlychallenging<br />
microfi ber with high number of fi laments, pre-intermingling<br />
can be an attractive solution for improving the quality of<br />
the fi nal yarn, overcoming manufacturing problems and<br />
increasing overall machine performance.<br />
Furthermore special products manufactured with special<br />
intermingling jets can create competitive advantages. The<br />
<strong>eAFK</strong> machine offers the possibility for implementing the<br />
intermingling piping required for pre-intermingling at the<br />
fi rst feed.<br />
Intermingling<br />
Regular and high quality intermingling is crucial to success<br />
especially for downstream weaving applications and here for<br />
warp yarns. To achieve the best-possible intermingling, the<br />
<strong>Oerlikon</strong> <strong>Barmag</strong> <strong>eAFK</strong> includes the so-called intermingling<br />
zone upstream to the secondary heater. It comprises<br />
two feed systems (G2 and the additional G2x) that allow<br />
stable and controlled yarn processing within a defi ned<br />
14 <strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
area. The integrated intermingling piping, equipped with<br />
straight couplings, offers easy handling and operation of the<br />
respective jets.<br />
Detorque<br />
In the event that customers wish to produce close to zero<br />
torque yarn without the need to ply yarns, <strong>Oerlikon</strong> <strong>Barmag</strong><br />
offers a detorque intermingling system for the <strong>eAFK</strong>.<br />
Located between the secondary heater and the third feed<br />
unit the intermingling piping can be equipped with special<br />
jets that create a yarn that is not completely without torque,<br />
but with minimal torque. Detorque works only with PET<br />
and requires a set heater. It is an alternative to plying yarns,<br />
which reduces the takeup capacity of the respective DTY<br />
machine by half (for 2-ply), in the event that the yarn is plied<br />
on conventional rather than Multispindle machines.
Take up zone<br />
Oiling solution – single deck<br />
The application of oil is important for smooth operation throughout most processes within the textile<br />
process chain. Depending on the downstream setup, a certain amount of oil may be required for higher<br />
effi ciency and less disruptions. Oil applied in one step of process is usually consumed or eliminated<br />
during the following process step, only again to be applied if required in the next step. For some products<br />
and downstream processes, oil is particularly undesirable, as in the case of dyeing applications, for<br />
instance. Respectively, a certain technical fl exibility must be considered.<br />
The location of the oiling device, the form of oil application and the polymer type can infl uence the<br />
process and are therefore important for effi cient operation and high-quality production.<br />
Single deck oiling is standard for the <strong>eAFK</strong>. Small and tightly<br />
covered oil troughs are located in front of each take-up<br />
deck. The latest-technology application rollers with a V<br />
groove along the yarn path apply the oil depending on stepfree<br />
setting of rotation speed. This solution allows the most<br />
accurate oil application, while simultaneously eliminating<br />
staining caused by potential oil mist.<br />
Pneumatically actuated, the yarn is either being lifted out of<br />
the oil applicator during doffi ng for oilfree transfer tails or can<br />
be fi xed in this position for completely oil-free packages (e.g<br />
dye packages).<br />
The <strong>eAFK</strong> with single deck oiling provides the most even<br />
process conditions from package to package as well as from<br />
deck to deck, thus improving the overall production quality.<br />
<strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
15
Take up solutions<br />
With the further development of downstream processes, the requirements for the DTY package<br />
constantly increasing. The best-possible package formation and the related unwinding performance are<br />
decisive criteria for effi cient manufacturing with up-to-date technology.<br />
As standard, the <strong>eAFK</strong> is equipped with ATT (Advanced Take-up Technology), the latest technology for<br />
advanced density controlled package formation, in conjunction with an automatic doffi ng unit.<br />
ATT – Advanced Take up Technology<br />
The quantum leap in package building technology comes<br />
with a single-position drive solution, fewer mechanical<br />
components and computer-control of every single stroke<br />
throughout the package formation, providing signifi cant<br />
benefi ts for the manufacturer and for the product itself.<br />
Furthermore, ATT allows for special solutions, such as<br />
unique fl exibility in package geometry or quality indicating<br />
marking of packages, which have – until now – been<br />
impossible using mechanical take-up units.<br />
The individual position drives in process and maintenance<br />
increase the fl exibility during production and prevent<br />
unnecessary machine downtimes. A signifi cant lower<br />
noise level and a reduced number of mechanical parts,<br />
easy maintenance and improved accessibility round off the<br />
mechanical improvements achieved by ATT.<br />
Another highlight is the control of yarn tension during<br />
winding. In detail, this means the yarn tension profi le during<br />
winding cycle can be preselected in order to<br />
• actively control the decrease in winding tension<br />
• gradually lower the decrease in winding tension even<br />
down to a constant winding tension<br />
• higher package weight<br />
• even package density<br />
• prevention of yarn damage by reduced initial winding<br />
tension<br />
• unique features for winding dye packages<br />
A further feature is the choice of various take-up programs<br />
with an individual calculation of each stroke for even yarn<br />
distribution over the entire width of the package as well as<br />
uniform pressure distribution on the tube.<br />
16 <strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong>
IAD – Individual Automatic Doffer<br />
The further-improved individual automatic doffer of the<br />
<strong>eAFK</strong> is the culmination of <strong>Oerlikon</strong> <strong>Barmag</strong>’s experience in<br />
automatic doffi ng.<br />
Reliable doffi ng performance to ensure the highestpossible<br />
machine effi ciency is the result of a sturdy take-up section in<br />
low-vibration design combined with <strong>Oerlikon</strong> <strong>Barmag</strong>’s CPC<br />
(contact pressure control) bobbin lever system. Adjustable<br />
for different package densities, it allows in conjunction<br />
with the <strong>Oerlikon</strong> <strong>Barmag</strong> TUP (Take-up Processor) - the<br />
best-possible package formation with excellent take-off<br />
performance.<br />
During the doffi ng procedure, waste injector systems<br />
transport waste yarn into easily accessible bins located on<br />
the creel side of the machine.<br />
Apart from the considerably reduced noise level due to<br />
use of the ATT system in the take-up section, the basic<br />
functionality of the IAD is the production of packages of<br />
uniformly-metered length.<br />
Two parking positions, in conjunction with one further full<br />
package in production, allow unattended operation for<br />
longer periods of time, depending on yarn titer.<br />
The <strong>eAFK</strong> take-up solution with ATT and IAD provides<br />
• Positions: up to 288 pos<br />
• CPC bobbin lever system<br />
• Winding of taper-ended packages with nominal taper<br />
angles of 65°- 90°<br />
• Max. package diameter - 250 mm<br />
• Basic (max.) traverse stroke length - 250 mm (273 mm)<br />
• Max. double strokes per minute ≤800<br />
• Package formation<br />
• Traverse drive with ribbon breaking unit as well as with<br />
scattering system variable for highest process speeds<br />
• Automatic doffi ng<br />
•<br />
Two parking positions<br />
Take up Package<br />
formation<br />
Package<br />
shape<br />
Taper<br />
angle<br />
Density<br />
control<br />
Double<br />
strokes<br />
ATT +++ +++ ++ +++ ≤800 ++<br />
Maintenance<br />
<strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
17
Cross sections…<br />
Although the <strong>eAFK</strong> allows a high fl exibility in conjunction with<br />
components, some cross-sections have proven to be the most<br />
suitable options for certain products and processes.<br />
For processing of fi ne to mid or mid denier with high number of fi laments, the<br />
V cross-section has been most successful. When processing such yarns, length<br />
of texturing zone, suitable heating-cooling combination and friction are to be<br />
considered. Various combinations are available using Dowtherm and HTI<br />
heater technology.<br />
For mid to coarse denier depending on number of fi laments and fi nal product<br />
requirement V or M crosssection can be selected. V type is more suitable for the<br />
mid, whereas M type is clearly more suitable for coarse denier with low number<br />
of fi laments. When selecting the components required for such product portfolio<br />
also the right choice of feed system has to be put into consideration.<br />
For coarse to heavy denier the M type upper structure is the most suitable crosssection<br />
for processing products with high denier per fi lament and total denier.<br />
As feed system shaft with nip roller due to draw forces implemented by coarse<br />
products has to be selected.<br />
The <strong>eAFK</strong> is designed to process all kinds of polymers in best possible manner.<br />
For polymers that typically do not require heat setting such as PA or PP can<br />
similarly well processed on the following cross-sections by minor changes to the<br />
machine: the secondary heater is being substituted with yarn guiding elements.<br />
<strong>eAFK</strong><br />
very fi ne<br />
20-50<br />
fi ne 50-75<br />
18 <strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
Process<br />
Products Dpf Advantage<br />
mid 75-150<br />
high mid<br />
150-220<br />
coarse<br />
220-300<br />
standard • • • • • • •<br />
coolfl ex • • • • • • • •<br />
0.2-0.5<br />
Multispindle • • • • • • • • •<br />
HTI • • • • • • • • •<br />
HTI coolfl ex<br />
1.0/1.2<br />
HTI coolfl ex<br />
1.0/0.8<br />
• • • • • • • • • • • •<br />
• • • • • • • • • •<br />
PA standard • • • • • •<br />
PA coolfl ex • • • • • • •<br />
0.5-1.0<br />
1.0-5.0<br />
quality<br />
fl exibility<br />
speed<br />
energy<br />
saving<br />
special
<strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
19
Dowtherm* upper structures<br />
Fine to conventional denier, versatility, process speed, PET/PA/PP/PTT/PLA<br />
<strong>eAFK</strong> standard: V 2.0 DT/ 1.1 P<br />
The most versatile conventional cross-section using Dowtherm heater technology. Comprising a 2.0<br />
m heater in combination with a 1.1 cooling plate this V cross-section combines versatility and a wide<br />
operational window. It is suitable for most commodities in a range between 30 to 300 den with best<br />
operational range between 50 and 220 den. Comprising the straight yarn path of the V cross-section<br />
low tension and high draw ratios can be achieved resulting in excellent manufacturing speeds, making<br />
this cross-section a standard in the industry.<br />
Versatility for effi cient and high quality production is achieved by…<br />
–<br />
–<br />
–<br />
–<br />
reduced friction<br />
elimination of contact points<br />
implementation of heater and cooling with greater operational window<br />
straight yarn path<br />
Suitable for micro fi lament yarns and fi ne to mid denier, while allowing greater operational window for<br />
higher denier<br />
20 <strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
*Dowtherm is a trademark of Dow Chemical
<strong>eAFK</strong> coolfl ex: V 1.5 DT/ 0.8 T<br />
The coolfl ex upper structure is optimized for processing very fi ne denier or products with very low fi lament count by means<br />
of a shorter Dowtherm heater in combination with a 0.8 m cooling tube. The 1.5 m heater allows energy savings of up to<br />
15% in comparison to the 2.0 m version. The 0.8 m cooling tube provides increased cooling capacity on shorter length and<br />
can be further optimized according to product requirement by adjusting the wrapping angle. This results in an operational<br />
window that especially favors fi ne denier and allows to process products even down to 20 den at even higher process<br />
speeds than the standard cross section.<br />
Improved processing of very fi ne and micro yarns is<br />
achieved by...<br />
–<br />
–<br />
–<br />
–<br />
optimized heater length<br />
improved and fl exible cooling<br />
shortest possible texturing zone<br />
less stress to yarn with selected components<br />
Suitable for super micro fi lament yarns and very fi ne to fi ne<br />
denier, opening operational window for these products while<br />
contributing energy saving<br />
<strong>eAFK</strong> Multispindle: V 2.0 DT/ 1.1 P x 2<br />
The Multispindle upper structure allows processing double the number of yarn ends for production of non-torque yarns in a<br />
product range of fi ne to mid denier with low to conventional fi lament count. While plying yarns on conventional machines the<br />
take-up capacity is reduced by half, thus increasing the number of yarn ends for treatment before being plied doubles the<br />
take-up capacity. Prerequisite for such processing is the limitation of single yarn ends to 220 den considering the fi nal denier<br />
of the plied yarn. This results in an operational window that favors fi ne to mid denier including low single fi lament yarns.<br />
Improved processing of plied fi ne to mid denier yarns is<br />
achieved by…<br />
–<br />
–<br />
–<br />
doubling the number of yarn ends per heater<br />
doubling the number of cooling plates<br />
doubling the number of texturing positions<br />
Suitable for micro fi lament yarns and fi ne to mid denier,<br />
opening operational window for plied products<br />
<strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
21
HTI upper structures<br />
Optimized operation window and versatility, highest process speed, PET/PP/PTT/PLA<br />
<strong>eAFK</strong> HTI: V 1.0 HT/ 1.75 P<br />
To widen the operation window the electrical HTI heater can be used. With its temperature range of up<br />
to 550°C in addition to fl exibility provided by <strong>Barmag</strong>’s patented insert technology it allows to process<br />
yarns at potentially higher process speeds. In order to compensate for the temperature increase the<br />
cooling capacity has to be adapted proportionally. The conventional HTI version comprises a 1.75 m<br />
cooling plate which provides a cooling capacity that allows to process fi ne to mid denier at highest<br />
possible process speeds.<br />
Versatility for effi cient and high quality production at highest process speeds is achieved by…<br />
–<br />
–<br />
–<br />
–<br />
increased heating capacity<br />
increased cooling capacity<br />
opening the operational window while shortening the texturing zone to 2.75 m<br />
straight yarn path<br />
Suitable for fi ne to mid and coarse denier in the range of 30 – 300 den with an optimized<br />
operational window<br />
22 <strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong>
<strong>eAFK</strong> HTI coolfl ex 1.0/1.2 active: V 1.0 HT/ 1.2 T<br />
To further widen the operation window the HTI heater is paired with <strong>Barmag</strong>’s cooling tube technology, that while shortening<br />
the texturing zone increases the cooling capacity beyond the capacity of the 1.75 m plate for the most demanding products.<br />
The ambient air cooling effect can be boosted with activation of air conditioned cooling thus allowing to optimally process<br />
products with different processing requirements fl exibly and by elimination of all bottle necks with the highest possible<br />
process speed exceeding the conventional HTI version.<br />
Versatility for effi cient and high quality production at highest<br />
process speeds is achieved by…<br />
– increased heating capacity<br />
– increased cooling capacity with active air cooling option<br />
– opening the operational window while shortening the<br />
texturing zone to 2.2 m<br />
– straight yarn path<br />
Suitable for fi ne to mid and coarse denier in the range of<br />
30 – 300 den with an optimized operational window<br />
<strong>eAFK</strong> HTI coolfl ex 1.0/0.8 active: V 1.0 HT/ 0.8 T<br />
Similarly to the Dowtherm heater coolfl ex version the HTI heater can be paired with the shorter cooling tube of 0.8 m<br />
length. Although decreasing the cooling capacity limits the operation window the shortening of the texturing zone leads to<br />
optimization for very fi ne denier and super micro yarns. The limitation is partially compensated with the also in this version<br />
available active cooling technology.<br />
Versatility for effi cient and high quality production at highest<br />
process speeds is achieved by…<br />
–<br />
–<br />
–<br />
–<br />
–<br />
increased heating capacity<br />
optimized cooling capacity with active air cooling option<br />
optimizing the operational window while shortening the<br />
texturing zone to 1.8 m<br />
straight yarn path<br />
Suitable for very fi ne to mid denier in the range of 20 – 200<br />
den with an optimized operational window<br />
<strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
23
Plant Operation Center<br />
POC – Plant Operation Center – is the all-embracing<br />
workfl ow management system from <strong>Oerlikon</strong> <strong>Textile</strong>.<br />
It is designed to detect and optimize the production<br />
processes within a production stage, e.g. spinning,<br />
or overall production stages – starting with the raw<br />
material up to the end product.<br />
Today, companies are confronted with challenges on all<br />
fronts: market requirements are becoming increasingly<br />
diffi cult to plan, pressure on margins is growing and the<br />
production environments of dynamic companies are<br />
becoming ever more complex. Within companies, data<br />
The POC creates transparency - the “Job Reports”<br />
module (Bild TEX JobReport1.tif)<br />
The POC Job Reports gives us an up-to-date and exact<br />
summary of all manufacturing jobs in the line. The summary<br />
includes information on both, complete manufacturing jobs<br />
and those still running. These informations are refreshed with<br />
each doff and for each package, respectively. Consequently,<br />
they are very precise at any time. The corresponding views<br />
show the current information per job, per machine and per<br />
position. As an option the POC interface to ERP can be used<br />
to forward the data of already fi nished manufacturing jobs to<br />
a customer ERP system.<br />
24 <strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
transparency, integrated processes and effi cient resources<br />
planning are becoming success factors.<br />
The POC connects the production hall with the<br />
management and creates the link between the ERP system<br />
and the control center. The various POC modules offer<br />
you the ideal tools to further increase the productivity and<br />
effi ciency of your systems. The software is modular, allowing<br />
you to create a customized system from the POC modules<br />
that is tailored to your precise requirements and that can be<br />
expanded at any time.<br />
The POC simplifi es the workfl ow - the “Recipe<br />
Management” module (Bild TEX Recipe Management.tif)<br />
The POC Recipe Management provides a central plant wide<br />
management of recipes. With the POC Recipe Management<br />
machine settings can be stored and transferred to recipes.<br />
Those recipes can be archived, printed, validated, edited,<br />
and then downloaded back to any machine connected. The<br />
Recipe Management automatically checks, if the desired<br />
set of information matches the physical arrangement. The<br />
POC Recipe Management has to be part of the system, if a<br />
connection to ERP (e.g. SAP) systems will be implemented,<br />
as it is the interface between an order/offering system and<br />
the real process settings for the machines.
Upstream processes<br />
Consulting, engineering, plant construction and<br />
high-tech machinery – the whole package from a<br />
single source. Many years of experience in textile<br />
machine construction and <strong>Oerlikon</strong> <strong>Textile</strong>’s strong<br />
global network form a solid basis and the perfect<br />
prerequisites for <strong>Oerlikon</strong> <strong>Barmag</strong> as a solutions<br />
provider.<br />
Plant engineering<br />
The growing demand for engineering services -<br />
particularly from various newcomers to the fi ber/fi lament<br />
manufacturing and processing sector - has resulted in the<br />
setting up of an <strong>Oerlikon</strong> <strong>Barmag</strong>-internal engineering<br />
division. A harmonized chain of polycondensation, spinning<br />
and texturing machines allows effi cient production which<br />
results in an increase of added value for the customer.<br />
Furthermore, <strong>Oerlikon</strong> <strong>Barmag</strong> will cater for a harmonization<br />
of all machines and lines in an optimal way and will provide<br />
the respective know-how.<br />
Polycondensation systems<br />
The quality of raw materials is a decisive factor in the quality<br />
of the fi nal product. Only vertically-integrated companies<br />
control all levels of the value-added chain, all others are<br />
reliant on their suppliers.<br />
With <strong>Oerlikon</strong> <strong>Barmag</strong> polycondensation, the yarn producer<br />
will reduce dependencies and will be able to determine the<br />
characteristics of the raw material. With more than 80 years<br />
of experience, <strong>Oerlikon</strong> <strong>Barmag</strong> knows the requirements of<br />
fi lament spinners and converts them into process-optimized<br />
systems concepts.<br />
POY spinning<br />
With more than 30,000 spinning units supplied in the last<br />
10 years, POY systems are the most successful <strong>Oerlikon</strong><br />
<strong>Barmag</strong> product. Several decades of continuous research<br />
and development today allow all customers to produce the<br />
most varied POY fi laments effi ciently and cost effectively.<br />
<strong>Oerlikon</strong> <strong>Barmag</strong> POY systems supply the best package<br />
quality and thus guarantee the highest pull-off speeds and<br />
an excellent dyeability of standard titers, microfi laments and<br />
high-count yarns.<br />
<strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
25
SUN - Service Unlimited<br />
Getting you to the top<br />
What are your expectations when you are deciding on new<br />
product ranges and equipment for your textile business?<br />
Do you really want to have several providers to manage the<br />
complex manufacturing processes you need to control?<br />
And can you risk facing the situation that after a few years<br />
your investment may be virtually worthless? We at <strong>Oerlikon</strong><br />
<strong>Textile</strong> are convinced that you shouldn‘t accept any of<br />
these limitations. This is the reason why <strong>Oerlikon</strong> <strong>Textile</strong> has<br />
devised SUN – Service UNlimited – the new service initiative<br />
that our Customer Support offers with its brands <strong>Oerlikon</strong><br />
<strong>Barmag</strong>, <strong>Oerlikon</strong> Neumag, <strong>Oerlikon</strong> Schlafhorst and<br />
<strong>Oerlikon</strong> Saurer to all its clients who require more than just<br />
service. SUN is a bundle of differentiated services that add<br />
real value to your <strong>Oerlikon</strong> <strong>Textile</strong> hardware and your daily<br />
business in a fl exible way.<br />
Partnering for performance<br />
<strong>Oerlikon</strong> <strong>Barmag</strong> Service offers you a broad range of<br />
products and services to achieve your objectives – faster<br />
return on investment, shorter downtimes and process<br />
support. Based in Remscheid and in Suzhou, a pool of<br />
highly qualifi ed employees equipped to react fast and<br />
effi ciently to the most varied customer demands. From<br />
build out and start-up to process consulting – our team<br />
of experts is waiting to support you. Moreover, in line with<br />
“think globally, act locally” our worldwide network of service<br />
stations will always reach you - everywhere. Local repair<br />
shops as well as on site workshops at your production plant<br />
are characteristics of our service philosophy.<br />
Our spinning R&D center at <strong>Oerlikon</strong> <strong>Barmag</strong>’s<br />
headquarters in Remscheid is equipped with ten modules<br />
forming closed, self-suffi cient units with a total of ten<br />
spinning plants on various levels. All modules can be<br />
independently operated in accordance with the respective<br />
process requirements. The texturing R&D center at <strong>Oerlikon</strong><br />
<strong>Barmag</strong>’s texturing equipment hub in Suzhou provides all<br />
currently available <strong>Oerlikon</strong> <strong>Barmag</strong> draw texturing machine<br />
types as well as facilities to evaluate process and machine<br />
performance supported by our experienced team of<br />
engineers. At both locations customers can test their raw<br />
materials and products or develop new applications under<br />
optimum overall conditions.<br />
www.myoerlikon.com – access to success<br />
The my<strong>Oerlikon</strong> customer portal is up to date at any time,<br />
24 hours a day throughout the whole year. The customer<br />
portal has a clearly arranged and uniform home page of all<br />
26 <strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
Main <strong>Oerlikon</strong> <strong>Textile</strong> Service<br />
• Network Stations plus more<br />
than 120 agencies worldwide<br />
business units and their product lines. Our customers have<br />
online access to the latest documentation, tailor made<br />
for their machines The trouble-shooting manual permits<br />
a quicker and more effi cient elimination of problems via<br />
direct links. The SECOS e-Commerce system, well-known<br />
worldwide, is completely integrated. The Engineering<br />
tool supports and accompanies the entire engineering<br />
process from concept to the turn-key plant. Innovative<br />
ideas and new solutions are added continuously. The latest<br />
encryption technology guarantees the maximum data<br />
security at any time.
<strong>eAFK</strong> – <strong>Oerlikon</strong> <strong>Barmag</strong><br />
27
<strong>Oerlikon</strong> <strong>Barmag</strong><br />
Zweigniederlassung der<br />
<strong>Oerlikon</strong> <strong>Textile</strong> GmbH & Co. KG<br />
Leverkuser Straße 65<br />
P.O. Box 11 02 40<br />
42862 Remscheid<br />
GERMANY<br />
Phone +49 21 91 67-0<br />
Fax +49 21 91 67-12 04<br />
info.barmag@oerlikon.com<br />
欧瑞康(中国)科技有限公司<br />
<strong>Oerlikon</strong> (China) Technology Co., Ltd.<br />
No.9 Chang Yang Street<br />
Suzhou Industrial Park<br />
Jiangsu, 215024, P. R. China<br />
Phone +86 512 8188 5902<br />
Fax +86 512 8188 5988<br />
dty.info.barmag@oerlikon.com<br />
dty.service.barmag@oerlikon.com<br />
The information supplied<br />
in this brochure is for<br />
guidance only.<br />
We reserve the right to<br />
modify it at any time.<br />
TL-<strong>eAFK</strong> 11/06-1<br />
yaean design limited<br />
Subject to changes