Importance of symmetry in modern extrusion machinery technology
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Importance of symmetry in modern extrusion machinery technology. Dr. Angelo Sabatelli Regional Sales Manager . Content. Introduction. Market - Technical Yarn. symTTec – the machine for technical yarns. Sucessful start up in Russia. Market - Carpet Yarn.

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Importance of symmetry in modern extrusion machinery technology

Importance of symmetry in modern extrusion machinery technology.

Dr. Angelo Sabatelli

Regional Sales Manager


Content technology.

Introduction

Market - Technical Yarn

symTTec – the machine for technical yarns

Sucessful start up in Russia

Market - Carpet Yarn

symTTex – the machine for carpet yarns

Conclusion


Introduction
Introduction technology.

  • SwissTex Winterthur AG:

  • Is the worldwide leading manufacturer and a solution provider with a profound knowledge of BCF and T&I processes in the continous filament market.

  • Has taken over all activities of former Rieter Filament Yarn Technologies in December 2006.

  • Is based in Winterthur, Switzerland, with more than 80 employees.

  • Is present on a global basis with all desirable services to make our customers succesful with our equipment


Content technology.

Introduction

Market - Technical Yarn

symTTec – the machine for technical yarns

Sucessful start up in Russia

Market - Carpet Yarn

symTTex – the machine for carpet yarns

Conclusion


Technical yarn markets
Technical Yarn Markets technology.

  • World fibre demand 2005 for technical applications




Content technology.

Introduction

Market - Technical Yarn

symTTec – the machine for technical yarns

Sucessful start up in Russia

Market - Carpet Yarn

symTTex – the machine for carpet yarns

Conclusion


Symttec extrusion system
symTTec – Extrusion System technology.

symTTec stands for SYMmetry for TEChnical yarns

  • Production of 4 ends per position

  • Special focus is given to the melt distribution geometry over each position

  • All yarns have the same angle from the spinneret to the first contact points, improving the filament cohesion

  • Pulsation-free quenching has been improved to better homogenize cooling conditions of each yarn

  • Large inlet and special spin finish applicators allows a reduction of the angle and friction of filaments at draw panel’s inlet

  • 2 winders each with 2 ends in parallel offer a unique symmetric geometry on winding


Symttec draw winding position
symTTec – Draw winding position technology.

Different available take up configurations

  • The use of one or other configuration depends on the yarn end-properties.

  • CD300-winder or FW61-winder are used depending on the down-stream available equipments.

  • 4 Duos - 4 ends

    5 Duos - 4 ends


    Swisstex s solutions requirements for spinning part
    SwissTex’s solutions technology.Requirements for spinning part

    • Requirements for an optimized process

    • high process stability with optimized melt quality

      • no overheating of the polymer material

      • low shear rates

      • short residence time, equal for each single polymer flow

    • homogeneity from filament to filament ( no weak filaments!!!)

    • Subjects for research

    • screw geometry

    • mixing systems (dynamic in extruder, static in melt pipes)

    • melt pipes geometry (same length for each single polymer flow)

    • melt distribution in the spin pack

    • adequate filtration of the melt

    • holes distribution in the spinneret


    Symttec extrusion system1
    symTTec – Extrusion System technology.

    • Production of 4 ends with plying for high titers

    • Special focus is given to the melt distribution to have an adequate pipe geometry to each position and spin pack

    • All yarns have the same angle from the spinneret to the first contact points, improving the filament cohesion

    • Pulsation-free quenching has been improved to better homogenize cooling condition of each yarn

    • Large inlet and special spin finish applicators allows a reduction of the angle and friction of filaments at draw panel’s inlet

    • 2 winders each with 2 ends in parallel offers a unique symmetric geometry on winding – no difference between rear-middle-front bobbins

    spinbeam

    drawpanel

    winders


    Symttec spinning components
    symTTec – Spinning Components technology.

    Annealer - overheaters

    • Annealers are heaters installed below the spinnerets to reduce the yarn orientation at the take-up roll level and thereby to improve yarn draw abilities

    • Annealers are electrically heated and removable for spin pack installation

    • Heating height approx. 250 mm

    • Individual position annealer with common handling, allowing a very homogenous over heating of each yarn independent of its location on the position (yarns in the middle vs yarns at the exterior)

    Traditional design (common)

    SwissTex design (individual)


    Symttec spinning components1
    symTTec – Spinning Components technology.

    • Cross flow quench with innovative solutions

    • Cross flow system offers the best ratio between handling and performance

    • Quenching has to be of perfect homogeneity

      • Pulsation free

      • Air speed fine tuning

      • Easy adaptation of the airflow to the production requirement

    • Air has to be oil free and with controlled humidity (Optional supply of A/C unit for process air)

    • Quench cabinet is designed to give easy access to spin packs / annealers and to allow easy dismantling of rectifier for cleaning


    Swisstex s solution cooling

    SwissTex’s Solution - Cooling

    Performance

    Cross flow quenching  best ratio

    Handling,

    Resources


    Swisstex s solutions draw rolls
    SwissTex’s solutions - Draw rolls technology.

    • RIEVAP roll overview


    Swisstex s strategy
    SwissTex‘s strategy technology.

    Targets for PA 6 tire cord

    Average market data

    Immediate target

    Mid term target


    Swisstex s strategy1
    SwissTex’s Strategy technology.

    Tire Cord

    Coated fabricsMRGRopes and netsTransmission beltsConveyer beltsVarious applications

    Tenacity (cN/dtex)

    Elongation (%)


    Industrial yarn technology
    Industrial Yarn Technology technology.

    • PA 6 results - comparison to commercial products

    Shrinkage

    Tenacity / Elongation

    10

    9

    8

    7

    6

    5

    4

    3

    2

    1

    0


    Industrial yarn technology1

    Tenacity / Elongation technology.

    Shrinkage

    8

    7

    6

    5

    4

    3

    2

    1

    0

    Industrial Yarn Technology

    • PES SLS results - comparison to commercial products


    Content technology.

    Introduction

    Market - Technical Yarn

    symTTec – the machine for technical yarns

    Sucessful start up in Russia

    Market - Carpet Yarn

    symTTex – the machine for carpet yarns

    Conclusion


    Symttec successful start up in russia
    symTTec – Successful start up in Russia technology.

    • On time achievement of the mechanical and electrical installation

    • High yarn properties reached short time after the first introduction of polymer granulates into the system

    • High process stability

    • Easy and friendly handling


    Content technology.

    Introduction

    Market - Technical Yarn

    symTTec – the machine for technical yarns

    Sucessful start up in Russia

    Market - Carpet Yarn

    symTTex – the machine for carpet yarns

    Conclusion



    Carpet yarn market
    Carpet Yarn Market technology.

    • The yarn production capacities shows a solid growth with a c.a.g.r of approx 2%

    Global PP and PA BCF Production Capacity


    Content technology.

    Introduction

    Market - Technical Yarn

    symTTec – the machine for technical yarns

    Sucessful start up in Russia

    Market - Carpet Yarn

    symTTex – the machine for carpet yarns

    Conclusion


    Symttex bcf extrusion system
    symTTex – BCF Extrusion System technology.

    • 4 ends per position

    • System size according customer requirements

    • Titer range 700 – 6000 dtex

    • Full symmetry in the yarn path

    • High speed potential due to straight yarn path

    • Top loading rectangular spin packs

    • Featuring HPTex Texturing system

    • Improved ergonomics

    • New Twin Winder FW 12

    • System designed for OLQ features

    System Layout & Figures

    8 ends

    frame based designed concept


    Symttex filament formation
    symTTex – Filament Formation technology.

    • New Approach of Filament Spinning

    • New concept re-grouping Spin packs, Quench, Inter-floor tube and Draw panel inlet

    • Use of simulation software and institute support to modelise the filament cooling process

    • Better repartition of filaments in spin plates to optimize cooling air flow between the filaments

    • More homogeneous filament structure resulting in better consistency

    • The result is a very stable and efficient filament formation resulting in higher yarn quality at highest productivity

    Traditional quench/inter-floor tube concept

    Optimized quench/inter-floor tube concept


    Symttex draw panel
    symTTex – Draw Panel technology.

    • Full symmetrical yarn path

    • One piece finish application concept

    • New flexible inlet / mono block with two Mono’s

    • Long drawing zone

    • DUO 2 with extended working width

    • HPTex texturing system

    • Long orientation zone after texturing

    • Prepared for single/tandem intermingling and On Line Quality sensors

    • Featuring Twin Winder with simultaneous transfer

    Future-oriented Design for higher Quality and Economics


    Symttex texturing system
    symTTex –Texturing System technology.

    • HPTex is a friction-less split jet texturing system

    • 100% straight yarn path with no friction at jet inlet

      - Straight from rolls to cooling drum

      • Conical jets position to reduce inlet friction

    • Enlarged cooling drum with long cooling angle

    • Extended lifetime of texturing parts

    • Consistent yarn quality from position to position

    • Easier, further reduced maintenance

    Friction less HPTex Texturing System


    Symttex yarn results
    symTTex – Yarn Results technology.

    Better Coverage and Consistency in the Carpet

    • The KWH measuring method does not show significant difference in crimp value, whereas the yarn behaves totally differently in the carpet

    • Benefit for carpet producers is in the reduced weight of pile used for similar appearance and reduced streaks problems

    • This quality can be achieved with at a slightly higher speed and machine efficiency

    • The quality is also more constant in the time as no wear happens

    • Constant quality over a long period of time

    • Customer does not need to sort out the bobbins and can mix bobbins from a production lot

    Standard jets

    Sorted bobbins

    HPTex jets

    Non-sorted bobbins


    Content technology.

    Introduction

    Market - Technical Yarn

    symTTec – the machine for technical yarns

    Sucessful start up in Russia

    Market - Carpet Yarn

    symTTex – the machine for carpet yarns

    Conclusion


    Conclusion
    Conclusion technology.

    SwissTex – Leading technologies for extrusion systems

    • Market looks for new qualities and innovations

    • SwissTex has long experience and existing references

    • symTTex sets a new benchmark in the market thanks to its “true” symmetric and straight yarn path

    • With symTTex, new yarn qualities at high competitiveness are possible

    • SwissTex managed to become a system supplier for tire cord and industrial yarns

      •  Complete range of components

    • New distributing plate in the spin pack

      •  Very good filament regularity

    • High draw roll quality

      •  Homogeneous heating of the yarn

      • Avoiding surface defects

    • Pilot lines are effective production lines

      •  Trial results are valid and transferable to commercial scale installations


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