Importance of symmetry in modern extrusion machinery technology. Dr. Angelo Sabatelli Regional Sales Manager

Importance of symmetry in modern extrusion machinery technology.

Dr. Angelo Sabatelli

Regional Sales Manager

ITMA 2007 Preview Conference – dr. Angelo Sabatelli FMC/BSt 2

Content

Introduction

Market - Technical Yarn

symTTec – the machine for technical yarns

Market - Carpet Yarn

symTTex – the machine for carpet yarns

Sucessful start up in Russia

Conclusion

ITMA 2007 Preview Conference – dr. Angelo Sabatelli FMC/BSt

Introduction

• SwissTex Winterthur AG:

Is the worldwide leading manufacturer and a solution provider with a profound knowledge of BCF and T&I processes in the continous filament market.

Has taken over all activities of former Rieter Filament Yarn Technologies in December 2006.

Is based in Winterthur, Switzerland, with more than 80 employees.

Is present on a global basis with all desirable services to make our customers succesful with our equipment

3


Content

Introduction






Conclusion


Technical Yarn Markets

• World fibre demand 2005 for technical applications

5


World fiber demand 2005 per segment

6


Economics of technical yarn extrusion

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Content

Introduction






Conclusion


symTTec – Extrusion System

symTTec stands for SYMmetry for TEChnical yarns

• Production of 4 ends per position

• Special focus is given to the melt distribution geometry over each position

• All yarns have the same angle from the spinneret to the first contact points, improving the filament cohesion

• Pulsation-free quenching has been improved to better homogenize cooling conditions of each yarn

• Large inlet and special spin finish applicators allows a reduction of the angle and friction of filaments at draw panel’s inlet

• 2 winders each with 2 ends in parallel offer a unique symmetric geometry on winding


symTTec – Draw winding position

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Different available take up configurations

4 Duos - 4 ends 5 Duos - 4 ends

The use of one or other configuration depends on the yarn end-properties.

CD300-winder or FW61-winder are used depending on the down-stream available equipments.


Requirements for an optimized process

• high process stability with optimized melt quality

• no overheating of the polymer material

• low shear rates

• short residence time, equal for each single polymer flow

• homogeneity from filament to filament ( no weak filaments!!!)

Subjects for research

• screw geometry

• mixing systems (dynamic in extruder, static in melt pipes)

• melt pipes geometry (same length for each single polymer flow)

• melt distribution in the spin pack

• adequate filtration of the melt

• holes distribution in the spinneret

SwissTex’s solutionsRequirements for spinning part

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symTTec – Extrusion System

• Production of 4 ends with plying for high titers

• Special focus is given to the melt distribution to have an adequate pipe geometry to each position and spin pack

• All yarns have the same angle from the spinneret to the first contact points, improving the filament cohesion

• Pulsation-free quenching has been improved to better homogenize cooling condition of each yarn

• Large inlet and special spin finish applicators allows a reduction of the angle and friction of filaments at draw panel’s inlet

• 2 winders each with 2 ends in parallel offers a unique symmetric geometry on winding – no difference between rear-middle-front bobbins

drawpanel

winders

spinbeam


symTTec – Spinning Components

Annealer - overheaters

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SwissTex design (individual)

Traditional design (common)

• Annealers are heaters installed below the spinnerets to reduce the yarn orientation at the take-up roll level and thereby to improve yarn draw abilities

• Annealers are electrically heated and removable for spin pack installation

• Heating height approx. 250 mm

• Individual position annealer with common handling, allowing a very homogenous over heating of each yarn independent of its location on the position (yarns in the middle vs yarns at the exterior)


symTTec – Spinning Components

• Cross flow quench with innovative solutions

• Cross flow system offers the best ratio between handling and performance

• Quenching has to be of perfect homogeneity• Pulsation free• Air speed fine tuning• Easy adaptation of the airflow to the production

requirement• Air has to be oil free and with controlled humidity

(Optional supply of A/C unit for process air)• Quench cabinet is designed to give easy access to

spin packs / annealers and to allow easy dismantling of rectifier for cleaning


Cross flow quenching best ratio ResourcesHandling,

Performance

high cooling quality

Pulsation free

Air speed fine tuning

Appropriate profile

SwissTex’s Solution - Cooling

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SwissTex’s solutions - Draw rolls

• RIEVAP roll overview

RIEVAP 32 RIEVAP 34

Application T&I

BCF

T&I

Raw Material PET, PA6 (.6)

(PP)

PET, PA6 (.6)

(PP)

Temperature Range °C 45 – 250 (260) 45 – 250 (260)

Diameter (mm) 190 190

Length (mm) 300 400

Heated length +/- 1°C (mm) 250 350

Range of Tilting +/- 8° +/- 8°

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Immediate target

Mid term target

Average market data

SwissTex‘s strategy

Targets for PA 6 tire cord

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SwissTex’s Strategy

Elongation (%)

Ten

acit

y (

cN

/dte

x)

Tire Cord

Coated fabricsMRGRopes and netsTransmission beltsConveyer beltsVarious applications


Industrial Yarn Technology

• PA 6 results - comparison to commercial products

8

7

6

5

4

3

2

1

Shrinkage

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10

0

Tenacity / Elongation


Industrial Yarn Technology

• PES SLS results - comparison to commercial products

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7

6

5

4

3

2

1

0

Tenacity / Elongation Shrinkage


Content

Introduction






Conclusion


symTTec – Successful start up in Russia

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On time achievement of the mechanical and electrical installation

High yarn properties reached short time after the first introduction of polymer granulates into the system

High process stability

Easy and friendly handling


Content

Introduction






Conclusion


Carpet Market - Trends

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Carpet Yarn Market

1'700

1'800

1'900

2'000

2'100

2'200

2'300

2'400

2'500

1997 1999 2001 2003 2005 2007

'000 tons/year production capacity

year

• The yarn production capacities shows a solid growth with a c.a.g.r of approx 2%

Global PP and PA BCF Production Capacity


Content

Introduction






Conclusion


symTTex – BCF Extrusion System

• 4 ends per position

• System size according customer requirements

• Titer range 700 – 6000 dtex

• Full symmetry in the yarn path

• High speed potential due to straight yarn path

• Top loading rectangular spin packs

• Featuring HPTex Texturing system

• Improved ergonomics

• New Twin Winder FW 12

• System designed for OLQ features

8 ends frame based designed concept

System Layout & Figures


symTTex – Filament Formation

• New Approach of Filament Spinning

Traditional quench/inter-floor tube concept

Optimized quench/inter-floor tube concept

• New concept re-grouping Spin packs, Quench, Inter-floor tube and Draw panel inlet

• Use of simulation software and institute support to modelise the filament cooling process

• Better repartition of filaments in spin plates to optimize cooling air flow between the filaments

• More homogeneous filament structure resulting in better consistency

The result is a very stable and efficient filament formation resulting in higher yarn quality at highest productivity


symTTex – Draw Panel

• Full symmetrical yarn path

• One piece finish application concept

• New flexible inlet / mono block with two Mono’s

• Long drawing zone

• DUO 2 with extended working width

• HPTex texturing system

• Long orientation zone after texturing

• Prepared for single/tandem intermingling and On Line Quality sensors

• Featuring Twin Winder with simultaneous transfer

Future-oriented Design for higher Quality and Economics


symTTex –Texturing System

• HPTex is a friction-less split jet texturing system

• 100% straight yarn path with no friction at jet inlet

- Straight from rolls to cooling drum

- Conical jets position to reduce inlet friction

• Enlarged cooling drum with long cooling angle

• Extended lifetime of texturing parts

• Consistent yarn quality from position to position

• Easier, further reduced maintenance

Friction less HPTex Texturing System


symTTex – Yarn Results

Better Coverage and Consistency in the Carpet

• The KWH measuring method does not show significant difference in crimp value, whereas the yarn behaves totally differently in the carpet

• Benefit for carpet producers is in the reduced weight of pile used for similar appearance and reduced streaks problems

• This quality can be achieved with at a slightly higher speed and machine efficiency

• The quality is also more constant in the time as no wear happens

• Constant quality over a long period of time

• Customer does not need to sort out the bobbins and can mix bobbins from a production lot

Standard jetsSorted bobbins

HPTex jetsNon-sorted bobbins


Content

Introduction






Conclusion


Conclusion

• Market looks for new qualities and innovations• SwissTex has long experience and existing references• symTTex sets a new benchmark in the market thanks to

its “true” symmetric and straight yarn path• With symTTex, new yarn qualities at high competitiveness

are possible

• SwissTex managed to become a system supplier for tire cord and industrial yarns

Complete range of components

• New distributing plate in the spin pack Very good filament regularity

• High draw roll quality Homogeneous heating of the yarnAvoiding surface defects

• Pilot lines are effective production lines Trial results are valid and transferable to

commercial scale installations

SwissTex – Leading technologies for extrusion systems

Documents

Importance of symmetry in modern extrusion machinery technology. Dr. Angelo Sabatelli Regional Sales Manager