21st December 2016, Neumuenster
Oerlikon Neumag will be exhibiting state-of-the-art system concepts for BCF carpet yarn production from 14-17 January at Domotex, the leading fair for carpets and floor coverings. New Industrie 4.0 solutions from Oerlikon's Manmade Fibers segment will also be deployed for the first time. With the presentation of the new IPC 4.0 (Intelligent Plant Control) customer services, Oerlikon will also explore the future possibilities in the production of BCF yarns.
The system portfolio of the market leader from Neumünster, Germany, almost completely covers the requirements of carpet yarn manufacturers. Specifically, the company is observing a strong demand for the BCF systems S+ and Sytec One across the entire polymer and titre spectrum.
With over 1,000 positions installed worldwide, Oerlikon Neumag facilities produce over 1.6 million tonnes of BCF carpet yarn. Since their market launches in 2007 (Sytec One) and 2010 (S+), the systems have been optimised continuously.
The demand for multi-coloured carpets has grown significantly, with the market seeking a wide spectrum of colour separations in tricolour yarns, the company reports. Oerlikon Neumag's S+ system concept aims to offer the opportunity to produce the most diverse colour separations, from melange to strongly separated colours.
The Variomelt concept has been designed to offer highly flexible production of large and small batches of mono- and tricolour yarns: the unit can be modified from tricolour to monocolour production with three single colours in less than 45 minutes.
Long batch runtimes per monocolour extruder are said to ensure particularly efficient raw material utilisation. As usual, the diphyl-heated Variomelt spinning mill provides a constant, optimal spinning temperature, according to the manufacturer.
With the CPC (Color Pop Compacting) unit from Oerlikon Neumag, strongly separated yarns can be manufactured efficiently, the company explains. The individual threads are provided with yarn cohesion in the CPC unit before texturing so that they are no longer able to become so intermingled in downstream process stages, giving rise to a strongly colour-separated yarn.
Tricolour carpets must have a very uniform appearance, and an optimal tangle result in the BCF spinning mill is crucial for this. “These tangle knots are produced in defined spacings and thicknesses using RoTac, the company reports. “Thanks to this tangling option, uniform tricolour results that cannot be produced in conventional tangling units are achieved even at high speeds.”
More than 240,000 tonnes of PA6 melt-dyed and natural white BCF yarns are currently manufactured each year on the latest Oerlikon Neumag machines. The melt lines, which are especially optimised for these processes, are designed to ensure an optimal melt quality.
A specially designed plug guide under the texturing unit and a so-called V cooling drum help achieve the highest crimp uniformity and quality. The specially designed texturing components are said to meet the highest demands in the field of short-pile automotive applications.
Networked production has long since ceased to be a vision of the future, but the solutions on offer are often extremely complex. The new Multi Machine Access Center (MMAC) is geared specifically to customers seeking a solution specially tailored to their requirements.
The innovative MMAC permits monitoring of the Oerlikon Neumag textile machines, allowing the scope of visualisation to be modified to suit the customer's particular wishes. Since the MMAC is linked to the process control system, its highest specification offers a central overview of all applications offered by the control system.