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| Issue date:16/04/2009 |
| ATA Journal for Asia on Textile & Apparel - Apr 2009 Issue |
| Source:Journal for Asia on Textile & Apparel |
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| Shaded by the global economic slowdown, both the suppliers and users of textile machinery are trying to identify rising trends and less crowded market segments. Industrial textiles and compact spinning are among the areas for attention |
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| The new Preci FX drumless yarn traversing system from Oerlikon Schlafhorst makes it possible to use drumless yarn traversing for processing of bobbins. |
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Industrial textiles as a niche market
With the advancing global industrialization, and expansion of local infrastructures in such counties as India, Russia and China, geotextiles is considered as a market niche or a less crowded market.
In this segment, various customized products are available for differing applications. One of these highly specialized products is geogrids, for example, woven or non-woven and coated structures made from high-modulus polyester filaments, according to Oerlikon Barmag.
Geogrids are used to improve stability and strength of the soft, poorly load-bearing ground and slopes both for asphalt roads and unsupported construction sites and forest paths. Bridging critical points using geogrids is often less expensive and more durable than conventional measures such as replacing the soil or installing stabilizing pylons.
Geogrids can be used for reinforcing dams and embankments in road and railway construction. Geogrids permit the building of stable, precipitous embankments. At the same time, they are durable as they generally have a lifecycle of several decades.
The starting product for geogrids is industrial polyester yarns with medium titers of between 2000 and 3000 denier. To absorb high tensile forces, i.e. to stretch only minimally when subjected to loads, these multi-filaments must have a high degree of dimensional stability – or a high modulus of elasticity, Oerlikon Barmag says.
The yarns are plied into bundles and woven or made into wide-meshed grids using warp-knitting technology. The mesh width varies depending on the requirement, but lies between 15 and 30 mm in the case of most commercial geogrids. In sandy grounds, this open, tensile structure is interlaced with the ground or the fill, hence increasing the load bearing capacity.
In a final step, the polyester grid is coated. A PVC mantle provides grids with stability and long-term protection against mechanical damage and aggressive soils. For asphalt surfacing applications, coating reinforces the adhesion of geogrids between layers of asphalt by means of a bitumen emulsion.
To meet the market demand, Oerlikon Barmag Engineering introduced a complete system for geogrids, starting with solid state postcondensation (SSP) and its spinning plants all the way through to the coating machine.
Heavy denier yarns can be spun by industrial yarn machines of Oerlikon Barmag |
One example of Oerlikon Barmag's solutions is a heavy denier and super heavy denier machine concept, which is designed to produce up to dtex 13,300 per winding position.
These lines can produce such deniers as dtex 2,200, 3,300, 4,400 and 6,600. Beside the primary application in the geotextile or geogrid reinforcement, the yarn is also used for lifting slings, ropes and etc. Such applications mainly require high-tenacities and adhesive finishes. One of the main advantages is that such heavy deniers can be simultaneously produced on the spin-drawing winding machine without later plying in a further, downstream process.
This machine can be equipped with Oerlikon Barmag's latest godet development, the HFpower (HFp) godet, in order to meet the high drawing and shrinkage forces needed for these products.
The HFp godet, Oerlikon Barmag explains, combines an extremely high drawing force of 320 N and a withholding force of 5,000 N with a length of 535 mm and a diameter of 250 mm. Such technical features are essential for the production of high denier ranges such as four times dtex, 3,300 or dtex 13,300 total.
Oerlikon Barmag says its technologies allow users to enjoy high per-unit production capacities, while lowering per-thread investment and the per-kilogram operating costs of produced yarn.
The company has also introduced an innovative EvoQuench quenching system, opening up ways to manufacture new FDY quality products. A single spinneret suffices to manufacture products with a high number of filaments, e.g. 150f288 denier. Another method using DIO (double-in-one) spin packs offers improved efficiency and productivity.
The EvoQuench system can manufacture medium-complex FDY products efficiently. It also allows the possibility to produce high-end flat yarns that until now has required extremely elaborate processes or has not been possible at all. “This paves the way towards higher-value products and hence offers the opportunity to add new impetus to the fiercely-competitive markets and to exploit machines to a greater extent”, says Detlev Schulz, process engineer responsible for FDY processes at Oerlikon Barmag.
Gaining from compact spinning
Compact spinning technology is another area textile machinery suppliers have worked on to explore more efficient and potentially more profitable way of spinning.
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Suessen explains benefits attainable by Elite CompactSet system (left) |
Elite CompactSet V5, an upgraded version developed by Suessen, is a flexible and versatile compact spinning system in the market, and it can be applied to new machines by the OEM or retrofit to different ring spinning machines. It also provides universal applicability of components and structural groups, improved yarn quality, extended service life, less maintenance and maximum operational reliability in industrial application.
According to Suessen, the system can be used to accommodate with various business strategies of mill owners:
Quality improvement
Optimised utilisation of fibre substance (raw material)
Production increase
Substitution of products (carded instead of combed material)
Cost saving in raw material
Suessen also outlines a number of benefits brought by the use of compact spinning.
Advantages for yarn
Tenacity increased by up to 25%
Zweigle hairiness (fibres exceeding 3 mm) reduced by up to 85%, Uster (H) hairiness reduced by up to 30%
Elongation increased by 15% to 20%
Work capacity increased by up to 50%
Yarn irregularity often improved
IPI imperfections frequently reduced significantly
Advantages in spinning
Optimum utilisation of fibre substance
Substantially improved spinning stability
Possibility of reducing yarn twist by up to 10% with corresponding production increase
Ends-down rate reduced by up to 60%
Fewer fibres/inexpensive raw material
Fibre loss reduced up to 0.01%
Fibre fly definitely reduced
Automatic winding solutions meet market needs
Also developed to meet market trends is Savio's Polar/I - Direct Link System. The trend of linking ring frames with automatic winders is getting increasingly popular in low-labour-cost countries as the link solution gives the possibility of total quality monitoring of yarns, Savio notes.
Savio's Polar/I - Direct Link System |
Main features offered by the Polar/I system are:
Uninterrupted movement of bobbins from the ring-frame to the winder
A new designed yarn finder station to increase efficiency
Possibility of additional 2° and 3° yarn finder stations
Easy front access to yarn finder stations which are located along the machine sections
New intelligent “Savio Bobbin Identification System” to remove identified yarn defects.
The incoming bobbins are guided to the yarn finder station to be prepared for the following winding process, and then delivered to the winding heads. The end finder station is positioned along the winding heads housing, in order to allow a full operator monitoring and friendly intervention.
The machine can be equipped with additional 2nd and 3rd station, bringing the feeding capacity of up to 2700 bob/hour, depending on requirements for longer ring frames.
Each winding head has two spare bobbins in addition to the one under process with straight vertical yarn path. In case of the optional request of “Spindle Identification System”, an auxiliary station is provided to remove defective yarn from bobbin, Savio says.
Innovative winding and rotor spinning technologies
In the field of winding and splicing technology, the Autoconer 5 is another recent advancement made by Oerlikon Schlafhorst. Its high productivity and reproducible package quality are outstanding features, the company describes.
Preci FX drumless yarn traversing system of Oerlikon Schlafhorst |
The new Preci FX drumless yarn traversing system from Oerlikon Schlafhorst makes it possible to use drumless yarn traversing for processing of bobbins.
Additionally, the Autocoro technology can be used in rotor spinning. The Autocoro S 360 is depicted by Oerlikon Schlafhorst as the only semi-automatic rotor spinning machine worldwide. The system realises rotor speeds of up to 130,000 rpm and take-up speeds of up to 230 m/minute in practice. It also features a new DigiPiecing piecing technology to achieve high quality.
For wool processors, Oerlikon Schlafhorst highlights its Zinser CompACT³ system, which provides performance features such as an adjustable yarn structure, a separate compact vacuum and the self-cleaning compact units. The system also scores in terms of economy due to a significantly reduced outlay on cleaning and maintenance, the company concludes.
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| Copyright © Adsale Publishing Limited. Any party needs to reprint any part of the content should get the written approval from Adsale Publishing Ltd and quote the source "ATA Journal for Asia on Textile & Apparel", Adsale Textile English Website - www.AdsaleATA.com. We reserve the right to take legal action against any party who reprints any part of this article without acknowledgement. For enquiry, please contact Editorial Department. |
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| Copyright © Adsale Publishing Limited. Any party needs to reprint any part of the content should get the written approval from Adsale Publishing Ltd and quote the source "ATA Journal for Asia on Textile & Apparel", Adsale Textile English Website - www.AdsaleATA.com. We reserve the right to take legal action against any party who reprints any part of this article without acknowledgement. For enquiry, please contact Editorial Department. |
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