From the Sector

The Indian yarn manufacturer Polygenta, specialized on the manufacturing of sustainable recycling yarns, recently commenced production of recycled polyester FDY yarns at its facilities in Nashik. The yarn is produced using a combination of perPETual Global Technologies patented chemical recycling technology and Oerlikon Barmag’s direct spinning system equipped with the 32-end WINGS concept.

The spinning plant was commissioned by Oerlikon Textile India technologists in close collaboration with the process experts at Oerlikon Barmag, with various FDY products currently being developed. The yarn produced caters to the requirements of premium-segment clients demanding high quality, cost effective sustainable solutions.

As one of the world’s first companies, Polygenta has, since 2014, been producing 100% recycled POY and DTY from post-consumer PET using the patented chemical recycling process developed by perPETual Global Technologies. perPETual’s process reduces CO2 impact by more than 66% compared to virgin PET. The yarn is spun using Oerlikon Barmag systems and equipment. As a result, Polygenta is able to produce a wide range of DTY and FDY yarns that comply with the Global Recycled Standard (GRS).

The Oerlikon Manmade Fibers segment will be presenting itself at the Egy Stitch & Tex 2020 between March 5 and 8, 2020 in Cairo – with a clear focus on the needs of the African market. In Hall 1, Stand B2 The Oerlikon Barmag and Oerlikon Neumag experts will also be showcasing the comprehensive product and service portfolio of the world market leader for manmade fiber systems at the stand of Oerlikon’s representative ATAG Export & Import.

The spotlight of the Oerlikon Manmade Fibers segment’s trade fair attendance will be on two core technologies: the new generation of Oerlikon Barmag eAFK Evo texturing machines is to be unveiled within the African market for the very first time. It promises higher speeds and productivity with consistently high product quality, along with lower energy consumption and simpler operation vis-à-vis comparable market solutions. In particular, the numerous value-added features include two that convince with cutting-edge technology: the optimized, innovative EvoHeater and the EvoCooler, a completely newly-developed active cooling unit.

The second technology focus offers new opportunities for the Egyptian market and the Middle Eastern markets in particular: with Oerlikon Neumag’s BCF S8 monocolor and tricolor system, the segment will be unveiling its new carpet yarn production flagship. Superlative spinning speeds, up to 700 individual filaments, finer titers of up to 2.5 dpf – the performance data and technological finesse of the new system have already made a huge impression at numerous trade fairs and roadshows over the past year. The tricolor’s core component is the new, patent-pending Color Pop Compacting unit (CPC-T) for even more flexible and more even color separation. With the CPC-T, individually-controllable air pressures for each color provide pre-tangling, which accentuates the colors and hence makes more than 200,000 different shades possible. Whereas it has been very difficult to manufacture strongly color-separated or color-accentuated BCF yarns from polyamide 6 to date, this will in future be possible thanks to the CPC-T system. As a result of the new design, the CPC-T is now also suitable for processes with low yarn tensions.
 
Expanded product offering for manufacturing carpet yarns
Know-how covering all relevant technologies deployed in manmade fiber spinning plants enables Oerlikon – as the world’s only manufacturer – to expand its range of products and services for making carpet yarns. The POY- and texturing-based system concept is designed for a carpet and home textiles segment that demands particularly soft and bulky polyester yarns with BCF-like properties. Here, the aim is to produce yarns with titers of max. 1300dtex and typically more than 1,000 filaments, with typical products including, for example, 1300dtex f1152, 660dtex f1152 and 990dtex f768. The machine concept comprises the well-known WINGS HD POY winder, along with the eAFK Big-V texturing machine.

Oerlikon has invited all visitors to this year's Shanghaitex in China on a journey into the future of manmade fiber production. From 25 to 28 November 2019, the world market leader showed all its guests its vision of a sustainable and automated manmade fiber production at its 100 m² stand in Hall E1, D20: "Clean Technology. Smart Factory." was the motto of the future. And this was only a stone's throw away from reality at the stand. Because today Oerlikon was presenting the four ITMA Barcelona world premieres for efficient machine and plant concepts in a new, innovative industrial design. Together with numerous other innovations, all this forms the new DNA of the Oerlikon Manmade Fibers segment.

Launched to create new standards in texturing: the eAFK Evo generation of machines promises superior speeds, greater productivity and consistently high product quality, along with lower energy consumption and simpler operation vis-à-vis comparable market solutions. Oerlikon Barmag showed these wideranging capabilities at the trade fair with a high-end design from the new system platform. In particular, the numerous value-added features include two that are excelling with cool technology: the optimized EvoHeater and the EvoCooler, a completely newly-developed active cooling unit.

• Clean Technology. Smart Factory.

Remscheid – Oerlikon invites all visitors to this year's ITMA in Barcelona on a journey into the future of manmade fiber production. From 20 to 26 June 2019, the world market leader will show all its guests its vision of a sustainable and automated manmade fiber production in a virtual 4D showroom at its 1,000 m² stand in Hall 7, A101: "Clean Technology. Smart Factory." is the motto of the future. And this is only a stone's throw away from reality at the stand. Because today Oerlikon is presenting four world premieres for efficient machine and plant concepts in a new, innovative industrial design. Together with numerous other innovations, all this forms the new DNA of the Oerlikon Manmade Fibers segment.

The challenges for the manmade fiber industry are manifold and Oerlikon shows its customers solutions:

1. Choosing the right business model
Price pressure on fiber and yarn manufacturers is growing due to global market consolidation. Here it is important to position oneself correctly. Are you producing polyester, nylon or polypropylene for the niche market and skimming off good margins with innovative products and ingenious material properties, or are you looking for business success through economies of scale in the volume market such as the constantly growing apparel sector? Oerlikon has the right answers for both business models. And the most important thing: the market leader supplies all solutions from a single source. See for yourself at the world premieres of the machine and system concepts of WINGS FDY PA6, BCF S8 Tricolor and the revolutionary eAFK Evo texturing machine.

2. Finding alternatives for good personnel
Finding good operators in the manmade fiber industry is becoming increasingly difficult, even in emerging industrial nations such as China, India and Turkey. The solution is obvious. What, for example, the automotive industry achieved years ago with the 3rd Industrial Revolution is now also taking its course in the textile industry. And at the same time it is even shifting up a gear. In the next step, automation in combination with digitization will lead to new, sustainable production. Oerlikon will be showing how automation and digitization interact at ITMA. Self-learning machines and systems, artificial intelligence (AI), remote services and edge computing are just a few of the key words in the digital half of the new Oerlikon Manmade Fibers DNA.

3. Guarantee quality and traceability
The qualities of the fibers and yarns must meet the highest demands and their production must be traceable throughout the textile value chain. This no longer only plays an important role in the automotive industry, where safety is of paramount importance. Other branches of industry that use fibers, yarns and nonwovens also want to know where the raw materials they produce for consumer articles come from. Legal regulations are demanding this more and more frequently. Oerlikon offers optimal solutions with its DIN ISO certified manufacturing processes. More than half of the world's manmade fiber producers are convinced every day that the qualities produced on Oerlikon Barmag, Oerlikon Neumag and Oerlikon Nonwoven equipment are right – and all visitors to ITMA can do the same on site.

4. Efficient and sustainable production
In the future, the materials produced from manmade fibers must become part of a further improved global recycling economy. The recycling of polyester – with over 80% market share the most frequently used manmade fiber in the world – has not only been on the agenda since today. Oerlikon already has solutions at hand: from PET bottles to fibers and filaments, to textiles and carpets. ITMA is the next step. With the VacuFil® Oerlikon in cooperation with the subsidiary company BBEngineering presents the world premiere No. 4 – a recycling solution within a running polyester production with a waste-free approach.

Vision becomes reality
The Oerlikon Manmade Fibers segment thus demonstrates what the ITMA in Barcelona promises as the world's leading trade fair for textile machinery and plant construction: "Innovating the world of textiles – sourcing for a sustainable future". In Hall 7, A101, this is already reality.

• Oerlikon integrates automation solutions for largescale plants in technology portfolio

Remscheid, Germany / Pfäffikon, Schwyz, Switzerland - Oerlikon announced today that it has acquired Germany-based AC-Automation GmbH & Co. KG, an engineering company specializing in large-scale plant automation solutions for the textile and packaging industries. The two companies have been partnering since the early 1980s. The integration of AC-Automation in Oerlikon expands the market-leading technology portfolio of its Manmade Fibers Segment. It also marks a milestone in Oerlikon’s ongoing quest to offer innovative, fully automated and digitally networked Industry solutions in the manmade fiber industry.

The 60 employees at AC-Automation’s Bernkastel-Kues and Augsburg locations will become part of Oerlikon’s Manmade Fibers Segment, which includes the leading brands Oerlikon Barmag and Oerlikon Neumag. The move will expand the Segment’s business model, adding another key core component to its current offering of production plants and technology solutions from melt to yarn, fibers, andnonwovens. Ultimately, Oerlikon will be able to offer customers a total solution from a single source, including automation logistics for packaging, high-bay storage, and other areas, which complement its current market-leading spinning and process technologies for the textile industry.

"We see our expanded overall offering as an Industry solution, reflecting the future of an even more efficient, digitized and profitable chemical fiber industry, especially for large-scale plants with daily production capacity of several hundred tons of polyester, nylon, polypropylene, or other manmade fibers,” explains Georg Stausberg, CEO of the Manmade Fibers Segment. Manmade fiber producers from China — the world’s most important market, generating more than 70 % of worldwide manmade fiber production — as well as companies from other fast-growing markets such as India, Turkey and the USA are also relying on automated and networked Industry total solutions.

"The acquisition and integration of AC-Automation’s automation solutions will provide new opportunities for our manmade fiber business. It enables the Segment to increasingly position itself as an Industry solution provider in combination with our own digitization solutions,” says Oerlikon Group CEO Dr. Roland Fischer. “As a leading provider of advanced materials, surface solutions and materials processing including the engineering and production of polymer plants, this acquisition marks another milestone in Oerlikon’s strategy to strengthen its businesses and thus sustain profitable growth.”

"After such a long partnership, we are excited to be able to benefit even more in the future as part of a global player in the textile industry. Our market access will further improve with the help of the Oerlikon
Group's sales and service network. For my employees, I am very pleased to be able to bring them into an international Group, in which there would be new opportunities and perspectives for them personally,”
said Rolf Gänz, AC-Automation’s Managing Director.

Ten positions of the new Flex-6 concept for manufacturing polyamide 66 industrial yarns were recently commissioned at Sinowin Chemical Fiber Co., Ltd., China. Shortly before the exhibition Techtextil opens its doors in Frankfurt, Germany, from May 9-12, 2017 the Segment Manmade Fibers of the Swiss Oerlikon group has announced this project.
The benefits of the new machine concept include components that are optimized to the respective application, which considerably reduce the required space compared to conventional solutions and its optimized energy consumption. Oerlikon Barmag Sales Director Oliver Lemke: “With its new godet configuration, the Flex-6 concept promises an unparalleled price-performance ratio for the production of high-end yarns. Sinowin is therefore the first industrial yarn manufacturer in China to deploy our new technology.”

Sinowin is completely committed to creating value for its customers. Here, quality and innovative technologies are absolutely essential, confirms General Manager Sheng Jian Wang: “We are striving to become a leading ‘Made in China’ enterprise in the chemical fiber industry. For this, we require state-of-the-art technologies that manufacture quality products. Oerlikon Barmag has an excellent reputation – above all for the PA66 industrial yarn process. To this end, there was no other partner for us.”