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Report | August 2016

Barmag makes mother yarn process profitable

In conjunction with the WinFors winder, the Oerlikon Barmag spinning system configuration, designed especially for manufacturing mother yarn, guarantees profitable mother yarn production. The monofilaments produced from this are also extremely convincing in terms of their excellent yarn quality. The perfectly coordinated steps – from the spinning process all the way through to take-up – ensure optimum results in the subsequent, downstream splitting process.

When manufacturing mother yarn made from polyester (PET) or polyamide (PA) – the preliminary product for monofilaments – the later separation of the filaments must be monitored even during the spinning process. The yarn guide and take-up are attributed a central role: a good splitting process is dependent on the yarn path within the draw unit and the package build.

For this challenging PET or PA process, Oerlikon Barmag technology provides the necessary precise and gentle yarn handling. The spinnerets and quenching unit – whose design has been especially tailored to the requirements of mother yarn – prepare the evenly-cooled filaments for further processing by the system. A special yarn guide in the system supports successful splitting of the yarn. For take-up, the yarn is transferred to the WinFors winder, which has been developed specifically for sensitive yarns. Its cam shaft guarantees excellent package build and stable edges for packages even in the case of the critical, high single dpf in mother yarn filaments. The precise and gentle yarn displacement of the cam shaft concept in conjunction with the tried-and-tested Oerlikon Barmag ribbon breaking process ensures that the downstream splitting process is carried out efficiently and without any loss of yarn quality. The Oerlikon Barmag FDY mother yarn concept has been optimized for the typical monofilament thicknesses of 15, 20 and 30 dpf and the associated mother yarn types such as 180 den F12, 240 den F12 and 360 den F12. Proven components are deployed: from the extrusion unit, the type SP8 spinning system with its special design and long quenching unit for high single filament titers all the way through to the FDY draw unit with 4 godets (PET) or with 5 godets (PA).

Mother yarn with rising market potential

Mother yarn is the term used to describe multifilaments that – following the spinning process – are split to create monofilament yarns. Their area of application is broad: in addition to drapes, mosquito nets, apparel (organza dresses, saris, etc.), monofilaments made from mother yarn are also used in the automobile sector, in items of luggage and in sports apparel (shoes). Consequently, the demand for mother yarn is also increasing: according to market insiders, there was a global growth potential of more than 10 percent last year alone. Particularly in India, the changed requirements of the textile further processing sector have resulted in increased demand for mother yarn. The two-stage process for manufacturing monofilaments deployed to date no longer provides the necessary profitability to secure commercial success.

Oerlikon is one of the leading, globally-active technology groups with a clear strategy to develop into a leading provider of surface solutions, state-of-the-art materials and materials processing. The group invests in value-generating technologies, with which customers can be supplied with lighter and more durable materials that increase performance, improve efficiency and reduce the use of scarce resources. As a Swiss company with a history stretching back more than 100 years, Oerlikon and its in excess of 13,500 employees are present at more than 170 sites in 37 different countries. In 2015, sales totaled CHF 2.7 billion. The company, which invested CHF 103 million in research and development in 2015, employees more than 1,350 specialists for developing innovative and customer-oriented products and Services.

For further information: www.oerlikon.com

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