With this technology innovation, customers are able to better cater to changing market requirements and can stand out in a highly competitive industry despite increasing pressure on costs – regardless of whether with standard or niche products. For this, the developers Neumünster-based company targeted a new level of increased productivity and even broader product diversity. The BCF S8 aims to be the most efficient Oerlikon Neumag BCF plant.
This is being already underlined and supported by the performance figures, the results of tests and the operation of two pilot lines within the market: with up to 700 potential filaments per yarn end, the BCF S8 exceeds its sister system, the BCF S+ (400 filaments), considerably, guaranteeing finer titers down to 2.5 dpf at the same time.
Furthermore, the process speed of the new Witras III-37 winder is – at 3,700 m/min – higher than ever before, permitting increased throughputs of up to 15% compared to predecessor technologies. Overall, this innovation offers a system efficiency of 99% as well as potential energy savings of up to 5% per kilogram of yarn.
Innovative – from straight yarn paths to large cooling drums
Numerous innovations have enabled these advances. To this end, one key element above all has been optimised. The yarn path from the spinning system to the new, large cooling drum has been almost completely straightened.
This yarn path, unique to the BCF market to date, ensures that the individual filaments are subjected to minimum friction, hence considerably reducing yarn breaks and optimising the overall production process. Noteworthy here are the, for the first time, straight yarn inlet in the texturing head – guaranteeing superior yarn quality.
And the considerably reduced distance between the heating godet duo and the texturing head also has a positive impact on the texturing process. It ensures a more even twist to the yarn and reduces the compressed air consumption. The texturing chambers can be removed individually, which addi-tionally shortens servicing times. The now closed units provide the best possible protection for the texturing jets and lamellar chambers. The cooling drum now has a larger, 800-mm diameter, optimally and gently cooling the filaments – also benefiting the yarn quality. Furthermore, the cooling drum is equipped with a V groove for all polymers (PET, PA6 and PP) as standard. This ensures straight lay-ing of plugs and improves crimp evenness. The standard system package now also includes the al-ready-established RoTac3 tangling unit, which again significantly reduces compressed air consump-tion by around 50%.
First HMI process control system
Last but not least, an HMI-based (Human-Machine Interface) control system controls the system for the very first time. In this case, the interface between man and machine has been oriented on the daily requirements of users in BCF production. With its new ‘look and feel’, it supports intuitive operation and comes with smart features that simplify everyday work. To this end, the system offers – by means of a touch screen – direct access to important information, operating statuses and actual and target values at each take-up position.
A completely new ‘alarm philosophy’ also simplifies troubleshooting and malfunction analysis. Here, certain irrelevant error messages or messages on other follow-on errors can be suppressed using sophisticated filter mechanisms and not transmitted to the HMI system. As a result, the operator is able to acquire a better overview of the current status of the system and secure the planned operation.