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Special Feature | April 2018

Sytec One attaches efficiency to single thread

Single-end Sytec One is recommended for processes with high breakage rates, fine filaments, frequent colour changes or in general when demanding processes take up an increasing share in the business.

The market for the production of carpet yarn is increasingly evolving towards more demanding processes. However, beyond commodity products, standard plants can no longer fully exploit their advantages. From March 20-22, 2018, Oerlikon Neumag presented an economical alternative in Shanghai in hall W3, booth F03 at the Domotex asia/Chinafloor, the leading floor covering trade fair in the Asia-Pacific region: the BCF plant Sytec One with single-end technology.

If the requirements for the production of BCF yarns increase, for example, from recycled polyester or fine filaments, then this can also lead to higher breakage rates. Highly standardised production plants must then often strike compromises with regard to throughput, quality or cost-efficiency. In such cases, the Sytec One offers a good solution instead of the mostly three-end technology plants for standard processes.

Single-end technology with 98% productivity

This BCF plant works with only one yarn (end) per position, making it ideal for demanding production processes. The reason: when a yarn break occurs only one yarn tears, all other yarns continue to run. This not only simplifies troubleshooting, it also reduces the re-threading time. In addition, less waste is produced. As a result, the productivity of the Sytec One is still over 98 per cent for 10 breakages a day, while a plant with three-end technology only reaches around 92 per cent.

Faster processes due to a straight yarn path

In addition, the absolutely straight yarn path of the Sytec One enables significantly higher process speeds of up to 15 per cent in spinning and texturing processes compared to multi-end technologies. Higher total titers of up to 6,000 dtex can also be produced without any problems. The gentle yarn guidance also ensures minimum friction on the individual filaments. This means less yarn breaks and a more stable process.

Optimised key component: spinning pack

Last but not least, the engineers at Oerlikon Neumag have developed a new design for the spinning pack. This central component of every BCF machine significantly influences the yarn quality. The corresponding solution for the Sytec One optimises the polymer flow in the spin pack, thus reducing the polymer dwell time. This leads to shorter product and colour change times and increases the plant efficiency. In addition, the spinning packs were widened so that yarns with up to 500 filaments can now be produced.

The product mix is decisive

In view of these advantages, the single-end Sytec One is recommended for processes with high breakage rates, fine filaments, frequent colour changes or in general when demanding processes take up an increasing share in the business. “The product mix is decisive for the choice of technology,” sums up Alfred Czaplinski, Sales Manager BCF at Oerlikon Neumag.

Good business at the Domotex Hanover, Germany

In the run-up to the trade fair, the Domotex Hanover in mid-January was already proving to be a promising harbinger. With four lively trade fair days and contract conclusions in the lower double-digit million euro range, mainly from the European and Asian markets, the order intake for Oerlikon Neumag was very good.

Oerlikon is a leading global technology Group, with a clear strategy to become a global powerhouse in surface solutions, advanced materials and materials processing. Backed by the key ability to intelligently engineer and process surface solutions and advanced materials, the Group is committed to invest in value-bringing technologies that provide customers with lighter, more durable, more efficient and environmentally sustainable products. A Swiss company with over 100 years of tradition, Oerlikon has a global footprint of over 13,500 employees at more than 180 locations in 37 countries and sales of CHF 2.3 billion in 2016. The company invested CHF 94 million in R&D in 2016 and has over 1,000 specialists developing innovative and customer-oriented products and services.

With its Oerlikon Barmag and Oerlikon Neumag brands, Oerlikon Manmade Fibers segment is the world market leader for manmade fiber filament spinning systems, texturing machines, BCF systems, staple fiber systems and artificial turf systems and – as a service provider – offers engineering solutions for the entire textile value added chain. As a future oriented company, the research and development at this division of the Oerlikon Group is driven by energy-efficiency and sustainable technologies. With the expansion of the product range to include polycondensation systems and their key components, the company now caters to the entire process – from the monomer all the way through to the textured yarn.

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