final oerlikon manmade fibers seminar

Oerlikon Manmade Fibers SeminarSilvassa

Silvassa, 20th February 2014

Part 1 - Technical Session

AgendaTechnical Session

1 14:30 - 14:35 hrs – Welcome speech | Khurshed Thanawalla

214:35 - 14:50 hrs – Evaluating the textile value chain |

Markus Reichwein

314:50 - 15:10 hrs – Innovations in new spinning technology |

Detlev Schulz / Stephan Faulstich

415:10 - 15:25 hrs – Integrated Solutions for the Manmade Fiber

Industry: Poly-condensation | Achim Debener

5 15:25 - 15:45 hrs – New Staple Fiber Solutions | Max Hergenreder

615:45 - 16:05 hrs – Partnering for Performance – new Service Solutions |

Ramakant Katre

716:05 - 16:25 hrs – Logistics - Key to an efficient filament yarn

production | Volker Schmid

8 16:25 - 16:55 hrs – Break

Oerlikon Manmade Fibers Seminar

Khurshed ThanawallaCountry Representative - India OerlikonChairman & Managing DirectorOerlikon Textile India Pvt. Ltd

� Is Managing Director of Oerlikon Textile India Pvt Ltd. Since 2007.

� His association with Oerlikon began in 1985 as Managing Director, Barmag India Pvt Ltd.

� Recently in 2011 Mr. Thanawalla has been nominated on the Panel of Experts for formulating and drafting the textile machinery and components section of the 11th Five Year Plan.

� Mr. Thanawalla has a Bachelor of Commerce from the University of Bombay.




Markus Reichwein







Ramakant Katre

16:05 - 16:25 hrs – Logistics - Key to an efficient filament yarn production | Volker Schmid

7 16:25 - 16:55 hrs – Break


Markus ReichweinSenior ManagerProduktmanagement ApparelOerlikon Manmade Fibers

� Is the responsible for the Product management Apparel within Oerlikon Manmade Fibers since 2012.

� He joined Barmag in 1994 and the Barmag POY Research Team in 2000.

� In 2011 Markus Reichwein took over the responsibility for the IDY Research Team and the IDY machine concepts as a Senior Manager.

� After studying mechanical engineering he graduated with a Dipl. Ing. Degree.


Evaluating the textile value chain

Summary:

In today’s manmade fiber business environment with high competition and overcapacity it is increasingly important for the companies actively approaching the manmade fiber market to exactly know their customer demands and future trends and to have the right production concept in place to react on new requirements. The product management of Oerlikon Manmade Fibers evaluates the downstream needs, fabric trends and market conditions to be a competent partner for our customers and ensuring unique benefits and superior values with our technology.

Evaluating the textile value chainProductmanagement Oerlikon Manmade FibersSilvassa, 20th February 2014

Agenda

1 Productmanagement in OMF

2 Trends and Opportunities in the Indian and Worldwide Apparel Industry

3 Example: Ecofriendly Textiles

4 Example: Increasing quality demand in downstream

Product ManagementThe Product Mangement Team

Product Management

R. Straub

ApparelM. Reichwein

Technical Application

N.N.

Floor Covering R. Straub

Nonwoven Dr. I. Mählmann

Plant Engineering

M. Gröner-Rothermel

AssistanceM. Alkis

Market KnowledgeR. Schneider

J. Huljus

Product Management in the textile chain

RawmaterialProduction

Early Stage Processing

Spinning Textile Pre-processing

Textile processing

Finishing Retail & Distribution

ProductMakeup

Synthetic Fibers

NaturalFibers

Regener-atedPolymers

Polymeri-zationPolycon-densation(CP)

POY/FDY/IDY/BCF/Staplefiber/Nonwoven

DTY Knitting

Weaving

Dying andFinishing

Printing

Coating/ Laminating

InteriorTextiles

Technical Textiles

Nonwovens

Garments

Retailer

MerchantandWholesale

Contractorandsupplier

ATY/ Draw Warping/Cabling/ Twisting

Knitting

Printing

Carpets

Embroidery

AuxillaryMaterials

ATY/ Draw Warping/Cabling/ Twisting

The product management evaluates the textile value chain of our customers. Future trends in the textile world are being evaluated and translated into the new requirements coming up for our customers.

Indian Apparel Industry Changing trends and opportunities

Need-Based clothing

� Shirts

� Trousers

� Jackets

� Sarees

Occasion Specific Dressing

� Sports / Gym Wear

� Occasion specific ethnic wear

� Casual wear

� Office Wear

� Night Wear

� Party Wear

� Work Wear

Detail Oriented

� Design based assortments foroccasion wear

� Fast fashion

� Eco friendly apparel

� Functionalization of garments

Smart and Ecofriendly textiles

Past Today Future Trend

� Retail moves closer to production

� Production moves in low costcountries or closer to end consumer

piece dyeing

(dyeing of fabrics or finished products)

dope dyeing

(mixing colors into the polymer)

package dyeing

(dyeing of FDY or DTY bobbins)

Ecofriendly Textiles

Example: a 100 tpd plant per ton

Ecofriendly TextilesEcological Footprint of the dye process

[MWh]

Example for a

100tons/day plant

The powered 3DD mixer

Situation

Bobbin or fabric dyeing

Consumes a lot of electrical

energy, water, space and time.

Moreover the process generates

CO2 emissions and effluents.

Profile of the (powered) 3DD mixer

� The 3DD mixer is either attached to an extruder as a screw and cylinder extension.

� In direct spinning lines it is a stand alone hot melt extruder with a dynamic mixing function. It is used for feeding master batches or liquid additives in throughput volumes > 100 kg/h. .

Achievements

� almost no energy consumption� almost no C02 emissions� no water usage - no effluents� almost no space consumption� no time consumption

Savings

� Approx 140 MWh / 100ton of yarn/fabric� 30 tons of CO2 / 100ton� 1.000 m3 of water / 100ton vs. fabric

dyeing process

Ecofriendly Textiles

Circular knitting m/c

FDYFabric

processing

Weaving FDY SD>90%

Knitting FDY BR > 95%

Braiding

Rapier loom

Air-jet loom

Water-jet loom

Projectile loom

Warp knitting60%

Weft knittingApprox 40% Flat-knitting m/c

Tricot m/c

Raschel m/c

Shuttle

Shuttleless1,8% of all looms

Others(hosiery etc)

Indian Downstream Industrye.g. FDY downstream

Outdatedmachines

Modernization withhigh speed MC

Indian Downstream Industry Changes in the industry structure

Governmental modernization scheme in Indian downstream Industry

� major incentives like exceptions on import duty on modern textile machinery,

� aggregation of small enterprises in clusters

� skill development for workforce

� Reduction of energy consumption

Target => raise the Indian Apparel Industry competitiveness

Current situation Future target

Indian Downstream Industry - Upcommingrequirements from downstream changes

Weaving Knitting

� Modern shuttle less looms� Reduced energy consumption� Higher skilled labour� International competitive product quality

� High speed warp knitting machines withhigh productvitity

� Reduced energy consumption� Higher skilled labour� International competitive product quality

Effects on the yarn production

1. Increasing quality requirements for yarn2. excellent end to end and day to day uniformity=> Modern production machines are required for Man Made Fiber spinning.

Thank you.




Markus Reichwein

314:50 - 15:10 hrs – Innovations in new spinning techn ology |






Ramakant Katre



16:25 - 16:55 hrs – Break


Detlev SchulzDipl. Ing. Senior ManagerR&D Filament Processing

� Detlev Schulz is responsible for process technology of FDY spinning machines.

� In 1989 he joined Oerlikon Barmag's R&D department.

� In 1993 he was appointed team leader spinning machines.

� Since 1995 he is head of R&D FDY.

� Detlev Schulz holds a Diploma of applied Physics from the University of Wuppertal (Germany).


Stefan FaulstichHead of R&D Tex. of Oerlikon Barmag

� Is responsibility for R&D POY since 2011.

� Joined Barmag in 1990 as a start-up engineer for texturizing machines.

� In 2001 appointed as Head of Quality Management of the BU-TEX.

� Moved into the R&D department of Oerlikon Barmag in 2007 as Head of R&D Tex.

� Stefan Faulstich holds a Diploma (Master) of applied Physics from the University in Iserlohn (Germany).


Innovations in new spinning technology

Summary:

Since two years in China and one year in India the WINGS FDY technology is established in the market. The lecture informs about experience in machine operation and downstream performance.

Agenda

WINGS FDY Silvassa 2014

1 What is WINGS FDY?

2 Machines in the market

3 Benefits of WINGS FDY

4 Performance examples

5 Summary

What is WINGS FDY?

Totally new take up

machine concept for

production of textile

PET FDY yarn


Compact draw field contains three cold and four heateds-wrapped godets

What is WINGS FDY?


Draw field

Step one:Mechanical & heattreatment of yarn

Step two:Finish application and interlacing

Yarn treatment






5 Summary

WINGS FDY machines in the market

� About 300 WINGS FDY positions running in India

� About 1300 WINGS FDY positions running in China

� About 1000 positions with 32 ends

� About 600 positions with 24 ends

� Productivity: ~ 2,000 tons/day

� Main products:• 50 - 100 den (..150 den)• 1 - 3 dpf







5 Summary

Benefits of WINGS FDY

� Energy saving

� One operator string-up

� Identical yarn properties

� Proven for downstream

� Good performance

� Short time for first startup


WINGS FDY vs. i-QOON position

i-QOON, 24 ends

WINGS FDY, 24 ends

Energy requirement for winder drives, godet drives and godet heating

Energy-optimized process & components


27% energysaving

WINGS FDY, 32 ends

39% energysaving

Power consumption saving per end in take up, measured and confirmed figures

Conventional 24-ends FDY technology

Power consumers in a spinning plant


7%

36%

25%

32%

HTM system forspinning

Draw-windingsection

Air conditioning andrefrigeration

Compressed air

Conventional 24-ends FDY technology

Power consumers in a spinning plant


7%

36%

25%

32%

HTM system forspinning

Draw-windingsection

Air conditioning andrefrigeration

Compressed air

10% energy savingpotential throughWINGS FDY technology!

(24e machines)

10%

Yarn data

� Elongation at 30 % with tenacity of 4.5 cN/dtex possible (quality number: 25)

� Uster: Usually between 0.8 and 1.2 CV %

� BWS: Usually around 7 % with +/- 0.3 %

� Intermingling points: 12 - 15 / m (depending on the pressure)

� � Data identical to i-QOON


Uster customer sample dtex 83f36 sd rd (Oct. 2013)

Downstream IndiaHigh speed warp knitting


All WINGS FDY yarns match downstream requirement!!

Producer Product W/Knitting stops

(den) (rpm) (1/100m)

Ginza Industries 50f48 sd 2300 3 - 4

Hemal FilamentsWINGS FDY 50f36 y hbr

(on all 3 layers)2250 2 - 3

Laxmi Technical50f36 y br

50 f 24 sd rd2150 4 - 5

Milan Textiles 50f36 Y br 2140 - 2320 3 - 4

Siddhivinayak

Filaments50f36 Y br 2300 2 - 3

CMCWINGS FDY

50f36 Y hbr2400 4-5

Aadarsh GroupWINGS FDY

50f36 Y hbr2200 - 2500 2 - 2.7

Producer Product W/Knitting stops

(den) (rpm) (1/100m)

Ginza Industries 50f48 sd 2300 3 - 4

Hemal FilamentsWINGS FDY 50f36 y hbr

(on all 3 layers)2250 2 - 3

Laxmi Technical50f36 y br

50 f 24 sd rd2150 4 - 5

Milan Textiles 50f36 Y br 2140 - 2320 3 - 4

Siddhivinayak

Filaments50f36 Y br 2300 2 - 3

CMCWINGS FDY

50f36 Y hbr2400 4-5

Aadarsh GroupWINGS FDY

50f36 Y hbr2200 - 2500 2 - 2.7






5 Summary

WINGS FDY achievable performance figures


Key points for good production figures

� Stable raw material supply

� Optimized workflow

� Good house keeping






5 Summary

Summary


WINGS FDY is a new and compact take up machine for PET FDY

There is good production performance and downstream performance with WINGS FDY yarn

There is huge conversion cost saving through energy saving, and quick operation

Thank you.


WINGS POY 1800

Silvassa, 20th February 2014Stephan Faulstich

Agenda

Wings 1800 Silvassa 2014

1 Evolution of winders - Why 12 end?

2 Major points of R&D

3 Inspection intervals

4 Pilot project WINGS 1800/12 end

5 Performance data Pilot project

Product cycles in POY spinning - idealized


1975 1980 1985 1990 1995 2000 2005 2010

4 ends 6 ends 8 ends 10 ends 2x10 ends

WINGS 1800 - major points R&D


12-end draw unit� gathering� godets� intermingling

Traverse system� new sensor solution� 1800mm one piece roller� new string-up device

12: ∅ 114mm-chuck� 15kg� 120mm stroke/440mm� new clamping

16: ∅ 125mm-chuck� 10kg� 86mm stroke/440mm

Rear housing� segmented rotor� 17Nm drive


Key factor “bearing”Robustness, lifetime AND fatigue

Lifetime and fatigue calculation/prediction as a core competence for safety and reliability

Subprojects� Fatigue testing together with Fraunhofer, IMA Dresden, TU Clausthal� Load spectrum analysis, online measurement, NVH� Innovative new technologies of market leaders


WINGS 1800 Ultra slim clamping ∅∅∅∅114mm

piston

new slim spring tech.

inner clamp elem.

Reduced height:old: 9mmnew: 5mm = 55%

same outer tube dia. = 125mm

Metallurgy technologyInspection intervals


No prescribed inspection by Barmag during more than 30 years of usage

Replacement of wear-parts by customer only


Pilot customer 12-end, Hengyi ChinaCommissioning and start-up


Pilot customer 12-end, Hengyi ChinaPerformance


Pilot customer 12-end, Hengyi ChinaPerformance

� The level can be accepted by customer (red line): Less than 5 times/hr� Customer’s target (Yellow line): Less than 3 times/hr� The level of same product made in Hengyi High-tech. Wings POY 10end: Less than 3

times/hr. � The present level of this project: Less than 3 times /hr. And both of POY and DTY

customer are satisfied with present DTY running performance.

Thank you.





Markus Reichwein



415:10 - 15:25 hrs – Integrated Solutions for the Manma de Fiber




Ramakant Katre



8 16:25 - 16:55 hrs – Break


Achim DebenerPolycondensation and plant design of Oerlikon’sManmade Fibers Segment

� Achim Debener is responsible for Polycondensation and plant design of Oerlikon’s Manmade Fibers Segment (former Textile) since 2010.

� In 1993 he already joined the company as Startup Engineer and site Manager for automation plants.

� In between he worked for four years as Head of Project Management and Purchase in the automotive industry.

� Achim Debener is graduated as Master of Engineering.

Oerlikon Manmade Fibers

Silvassa, 20th February 2014

Brief History

Segment Manmade Fibers

SegmentAdvanced Technologies

SegmentDrive Systems

SegmentCoating

SegmentVacuum

� Machinery manufacturer

� Implementation and development of international

netwrok Modularisation

� Plant Design Step 1 (EP) Turn Key including

Performance & Product Guarantee.

� Plant Design Step 2 (EPC) “From Melt To Yarn“

1922 2000 2007 Today

� 2511 Employees 50% Asia

Global Engineering Network

BarmagRemscheid

Germany

OT IndiaMumbai

India

OTBBeijing China

Cooperations-partner

� Project Management (PM)

� Project planning

� Basic engineering

� Detail engineering

� Process and control systems

� Plant modelling

� Financial engineering

� Global sourcing

� Utilities and off-site facilities

� Supervision services

� Documentation

NeumagNeumünster

Germany

Engineering services

� approx. 150 employees

� approx. 200 projects/a

Oerlikon Manmade Fibers since Year 2000

Utilities (Air, Water, Nitrogen, HVAC, Energy, HTM, DCS, Effluent….)

CPContinuous

Polycondensationn

SSPSolid State

Polycondensation

SPI Take-Up

SPI Take-UpFDY

MEG

PTAmelt o. chips

chips

Quotation/ Consultant Project Service

On EP basis, (turn key)

SAP Status 2.0 SAP Status 3.0

BCF/StaplePOY/DTY

IDY/GEO

� Polycondensation

From Melt to Yarn

Oerlikon Manmade Fibers since Year 2007

Utilities (Air, Water, Nitrogen, HVAC, Energy, HTM, DCS, Effluent ….)

CPContinuous

Polycondensation

SSPSolid State

Polycondensation

SPI Take-Up

SPI Take-UpFDY

MEG

PTAmelt o. chips

chips

Quotation/ Consultant Project Service

On EPC Basis, if necessary

SAP Status 2.0 SAP Status 3.0

BCF/StaplePOY/DTY

IDY/GEO

� Polycondensation

From Melt to Yarn

Bottle Grade

Sales and Key projects - Success story

Country Capacity Plant type Contract type

India 3 x 200 t/d PET-Textile(full dull, bright, cationicDyeable - semi dull)

EP

India 1 x 300 t/d PET-Textile(semi dull)

EP

India 1 x 600 t/d PET-Bottle EPC

Egypt 2 x 600 t/d PET-Bottle EPC

Our next Step From - Melt to Yarn

Oerlikon Manmade Fibers covers two Processes of the entire Value Production Chain

Petro-chemicals

Melt Yarn Raw fabric Treated fabric

End product Application

Raw material PolymerProcessing

(CP)

Spinning TextileProcessing

Finishing ProductMake-up

Retail &Distribution

PTAMEG

Capro-lactam

Polycon-densation

Poly-merization

POY/DTYFDYIDYBCF

Staple fiber Nonwoven

SSP for Bottle Grade

Knitting

Weaving

Interior Textiles

Technical Textiles

Nonwovens

Garments

Carpets

Dying and Finishing

Printing

Coating/ Laminating

Retailer

Merchant& Whole-sale

Con-tractor & Supplier

Plant Areas – Generic Block Diagram

Customer benefits

Customer Benefits

OMF as

Solution Provider

OMF has a

competitive offering

� Technology provider over the complete chain

� Single Point responsibility from Concept to Commissioning

� Easier project management for customers, less interfaces, time management

� Service for financing, engineering project management to production

� Reliable partner

� World class procurement

� Global successful network, proven since many years within core business activities

� Global engineering footprint

� Ensures better return on investment (ROI)

Customer Benefits

� More than 90 years of experience in the Polymer industry

� Access to global service network

� Technical Services

� Value Engineering to optimize CAPEX and OPEX

� Improved plant performance

� Better yarn quality due to overall development and R&D activities

OMF offers

Other Value Addition

Thank you.




Markus Reichwein



415:10 - 15:25 hrs – Integrated Solutions for the Manmade Fiber Industry:

Poly-condensation | Achim Debener

5 15:25 - 15:45 hrs – New Staple Fiber Solutions | Max He rgenreder


Ramakant Katre



8 16:25 - 16:55 hrs – Break


Max Hergenreder

� Is Sales Manager for Staple Fiber equipment, with Oerlikon Manmade Fibers since 2007 (Oerlikon Neumag site).

� He joined the company already in 2003 as student trainee.

� Max Hergenreder graduated in Industrial Engineering and Business Studies from the University of Applied Science “Nordakademie” (Germany).


New Staple Fiber Solutions

Summary:

For many years, there has been a trend to increase the capacity of staple fiber production lines to accommodate the steadily mounting global demand for synthetic fibers. The main focus was on the economical production as well as profitability as major interest for investors. This is as true today as it was then. Now, Oerlikon Neumag developed a revolutionary new and innovative staple fiber solution for small capacity which meets these criteria. The unique design offers various advantages to the customer. The technology is in general capable for a wide range of products with respect to different polymers, fiber properties or application fields. Processing of PET recycling material using bottle flakes is as possible as production of bico fibers. The line is perfectly suitable for economical production of small lots including spun dyed products. The target market for the products is the fast growing nonwoven industry where the most Indian players are small and medium-sized enterprises.

Oerlikon Neumag ´sNew Staple Fiber Solutions

Silvassa, 20th February 2014Max Hergenreder

Agenda

1 Introduction – Staple Fiber Plants, Current Co ncepts

2 New Technology – Staple FORCE S1000

3 Applications fields – Nonwoven Markets

4 Technical Features

5 Your benefits

IntroductionThree Strong Technologies

BCF Staple Fiber Nonwoven

IntroductionStaple Fiber Plants - Current Concepts

One Step Continuous Staple Fiber Plant Inline

Two Step Discontinuous Staple Fiber Plant

Short spinning section, drawing, crimping and cutti ng

2. Step - Drawing, crimping and cutting1. Step - Spinning

~ 60 m/min ~ 200 m/min

~ 1200 m/min ~ 70 m/min

Introduction - Current ConceptsInline Staple Fiber Production

Introduction – Current Concepts2-step Staple Fiber Production

Staple fiber plantformproduction ofcommodity fibers

Capacity up to300 tons/day

Introduction – Current ConceptsLarge Scale Production of Staple Fibers

Agenda

1 Introduction – Staple Fiber Plants, Current Concepts




5 Your benefits

Staple FORCE S1000 TechnologyRevolutionary New Design

Plant for economicalproduction of small lots

New staple fiber Capacityup to 15 tons/day

Focus on nonwovenapplications

Staple FORCE S1000 TechnologyLine Concept

spinning/quenching

drawing raw material supply

pre heatingoven

quench airunit

crimpingfiberdrying

cuttingbale pressing/ packing

Preliminary plant dimensions approx. 40m x 20m x 9m (length x width x height) without storage for raw material & finished products

Staple FORCE S1000Start-up of Pilot Line

Agenda





5 Your benefits

Nonwoven MarketsMarket Growth – Business Opportunities

4,91

3,52

2,76

3,80

2,85

2,31

5.0

2.0

4.0

1.5

3.5

2.5

3.0

4.5

2016201420122010200820062004

Disposable Nonwovens

Durable Nonwovens 9%

8%6%

6%

million tons

Nonwoven MarketsApplication Fields – Business Opportunities

348‘000 tons

539‘000 tons

9.1 %

333‘000 tons

510‘000 tons

8.9 %

105‘000 tons

151‘000 tons

7.5 %

341‘000 tons

486‘000 tons

7.2 %

323‘000 tons

536‘000 tons

10.7 %

767‘000 tons

1‘017‘000 tons

5.8 %

668‘000 tons

1‘127‘000 tons

11.0 %

Current Status of Indian Market Nonwoven Industry – Demand

� The Indian nonwovens industry is still in its infancy, with output of about 220’000 tons/year

� Fast growing segment generated a lot of investments in the recent past

� Great potential for consumer products like feminine hygiene, wipes, medical and other nonwoven disposables

� Large markets for automotive, geotextiles, filter products and other technical textiles

� The Indian Technical Textiles market has grown from Rs. 42,000 crores (US$ 9.49 Bn) in 2007-08 to Rs. 57,000 crores ( US$ 12.9 Bn) in 2010-11 registering a CAGR of ~11%

� There are over 3000 units manufacturing technical textiles. Most of the producers are SME

Current Status of Indian Market Fiber Industry – Supply

� Textile industry is the predominant segment. Main focus is on the production of PET commodity products (cotton-type fibers)

� Few big producers with medium-sized and high capacity lines

� R-PET gains significant market share, especially in fiberfill applications

� Supply of other fibers (PP, Bico) underdeveloped

Agenda





5 Your benefits

Technical FeaturesStaple FORCE S1000 Plant

Technical Features Spinning Equipment

Cover Spin Pumps

Flexible Heaters

Spin pack

Technical FeaturesDrawing EquipmentThe drawing is effected via godet duos with ferrit heating technology. They replace the conventional drawing section consisting of draw stands and draw chests.

16,30

A - A

A

A

Technical FeaturesCrimper� New compact design

� Stuffer box crimping principle (2D crimp)

� Working width 10 to 50 mm

� Stuffer box height adjustable

� Mechanical speed up to 1,500 m/min

� Crimper rollers with single-side bearings

� Thus, tow threading with suction gun at fullproduction speed possible, up to 1,200 m/min

� Easy to operate and to maintain

� I.e. easy accessibility to all parts (e.g. forcleaning, replacement of consumables)

� For assembly/disassembly of crimper rolleronly one screw, no further adjustmentnecessary

Technical FeaturesCutter� Well proven, reliable cutting technology

with horizontal Neumag cutting principle

� Cutting length down to 1.5 mm

� Cutting speed up to 2,500 m/min

� No machine stop for tow string-up

Agenda





5 Your benefits

Your BenefitsStaple FORCE S1000 Technology

Low Energy Consumption/ Energy Savings

High Throughputs

Low Waste Rate

With up to 210 kg/h per spinning position, our new technology is an economical alternative for staple fiber production.

Due to simplified, dry drawing process, energy balance for utilities has been significantly improved.

High machine availability and low waste rate during product change


User Friendly Design

Compact Plant Design

Competence in R&D

Minimum space requirements reduce initial investment

Due to easy handling, the plant can be operated by only two operators

Fully equipped (semi-)production pilot line with bicomponent capabilities

Full Scope Supply


Outstanding Flexibility & Product Variety

Uniform fiber quality

BicomponentCapabilities

Higher spinning speed, robust quench system, superior crimp technology and reliable cutting equipment ensure uniformity of fiber properties.

Our bicomponent spinning technology runs successfully in more than 25 installations world-wide.

Thank you.




Markus Reichwein






615:45 - 16:05 hrs – Partnering for Performance - new Ser vice Solutions |

Ramakant Katre



8 16:25 - 16:55 hrs – Break


Ramakant Katre

Head of Service Oerlikon Textile India

� Is Head of Service, Oerlikon Textile India Pvt.Ltd since 1996.

� He joined the company in 1996 as Manager (Erection and commissioning Services) for Barmag Spinning Machines.

� Before he worked as Production Incharge in a Polyester Filament Yarn spinning plants.

� Ramakant Katre has a Master of Technology degree in Fiber Science and Technology from Indian Institute of Technology, Delhi, a premier Technological Institute in India.

“There is only one proof of ability: action”

Planning

Executing

Start-up

– Marie von Ebner-Eschenbach

Barmag service already started in Baroda in early 1990s. Full Fledged Service Station was started in 1995.

Presently the Service Team from Baroda Service Station is not just only capable of trouble shooting the machines, but are experts for installations and start-up, project management, engineering, repair etc. in the area of spinning and texturizing machines.

Today they provide effective Service support for Oerlikon Barmag and Oerlikon Neumag machines in India as well as worldwide for the complete range of products

We started with DTY Service in early 1990s in Baroda with just 6 persons in customer service along with the first machine installation in India.

Today, out of about 95 employees, 40 are responsible for start-up, customer service, and repairs, 33 are taking care of on – site maintenance activity, with a support of 10 for spare part sales.

Apart from Repair shops at Baroda Service Station, On – Site Maintenance workshops are operative to take care of ACW and WINGS winders, Godets and pumps

OMF service history - India

Start-up

Process support

Technology

Core competencies

Partnering for PerformanceIndia Setup

Technical service

Service Station at Baroda is strategically

located very close to the major Man

Made Fiber producing area of Surat and

Silvassa/ Daman

Not only in Baroda, but as well at

customers workshops we repair and

maintain ACW and WINGS winders, Godets

and Pumps

Personal contact partner.

Dedicated service technician.

Remote diagnostics.

On your demand.

We started a process to reorganize our customer support in Oerlikon Manmade Fiber to meet our customers needs better.

Therefore we started having a detailed look not only into our technology, but as well to the different market needs.

We received valuable input from the interviews from our Indian customers.

We will increase our performance!

OMF Partnering for Performance

Detailed look

Partnering for

performance

Customer feedback

� When it’s out of warranty, it becomes very difficult to get concrete help from Barmag’s after-sales department. Now they are mostly interested in selling spare parts.

� Biggest pain points are spare part availability, lead times for orders, and repair return

� Current service structure and support level are driving a lot of issues for dissatisfaction

� No transparency regarding problem solving timeline, nor when things get done

� Experienced decreasing quality of Barmag machine spare parts, esp. outsourced spare parts

� For frequently occurring issues, it is too slow to wait for Barmag’supgrades, plus the costs paid to Barmag would be much higher than done in-house

Customer Complaints

Customers Recommendations

� A contracted “Barmag engineer on-site” model will be welcomed

� one person interface

� Guaranteed responce time

� willing to invest in potential tech consultation projects, to - Decrease operation costs- Increase energy efficiency- Improve product quality, by optimizing machine specs

� Need to see measurable results (cost and benefit analysis) for consulting

� Under an ideal model, we won’t need to ship any machines offsite for repair; everything can be repaired on-site.

� We already purchased a lot of testing equipment. If we invest more to set up a full scale service station on-site, supervised by Barmag engineer, that would be very convenient, and we can discuss about how each party should invest in this model.

We understood – Partnering for Performance

� Local stocks for higher availability, shorter lead times

� Increasing service employees targeting better customer intimacy(not only being available during installation of machines and for spare part sales

� More presence on-site during operations

� Efficiency improvements / Energy efficiency upgrades

� Proactive information about available solutions

� Ensuring succession solutions

� Recommendations/ support for preventive and predictive maintenance

� Quicker repair times

Centered around“Keep it running”

Focused around customers' strategic priorities : “Optimize”

Equipment availability

Performance(cost/ton)

Quality of endproduct

Customer focus

Active offering

Partnering for Performance

� Installation� Spare parts� Repairs

� Installation� Spare parts� Wear parts� Maintenance

and Repairs

� Upgrades� Expertise-

based services

Thank you.

File Name




Markus Reichwein







Ramakant Katre

716:05 - 16:25 hrs – Logistics - Key to an efficient fil ament yarn


8 16:25 - 16:55 hrs – Break

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Volker SchmidDirector Sales at AC-Automation

� Joined AC-Automation in 2009 with the takeover of product division “filament handling”

� Entered the filament automation department of AUTEFA automation in 1996

� Project design from 1996-1997

� Project Management 1998-2000

� Sales 2001-2003

� Director Sales 2004-2008

� Volker Schmid holds a Diploma in Mechanical Engineering from Augsburg University of Applied Science

AC Automation

-With „Autefa-filaments“ technology-More than 25 years of experience-Highly-sophisticated solutions for latestdevelopments-Represented by OTIL in India with professional support-Approx. 70% market share in India-Member of the Atlantic C Group of companies-Completely privately owned by Mr. Rolf Gänz-Group activities: Logistics and bottling lines forthe beverage and food industry up to palletwarehousing

-

Quality – Made in Germany

AC Automation

Headquaters andadministration in

Bernkastel-Kues, Mosel Region

Engineering offices in Augsburg, Bavaria

Warehouse and dispatchcenter at Mülheim-Kärlich

-3 locations in Germany:

-

CUSTOMER LOCATION SYSTEM TYPEBOBBINS PER DAY

SanghiIndoramaHyosungDuPontSaehanNan YaDuPontDuPontLan FaZig ShengFCFCNan YaNylmexHoechstShinKongShinKongShinKongShinKongDuPontSAKoSaNilit

IndiaIndiaKoreaGermanyKoreaTaiwanBrazilGreat BritainTaiwanTaiwanTaiwanUSAMexicoGermanyTaiwanTaiwanTaiwanTaiwanUSATurkeyIsrael

Fully automatic spinning plantFully automatic spinning plantAutomatic POY packing systemAutomatic POY storage/packing systemFully automatic spinning plantFully automatic texturing (AFK) plantAutomatic POY doffing/packing systemAutomatic POY transportation systemFully automatic texturing (AFK) plantFully automatic spinning plantFully automatic spinning plantFully automatic spinning plantFully automatic spinning plantAutomatic POY doffing systemFully automatic texturing plant (AFK/33J)Fully automatic spinning plantFully automatic spinning plantAutomatic DTY packing systemFully automatic spinning plantAutomatic tire cord doffing systemAutomatic POY doffing system

8.0007.8008.600

15.00020.00030.0008.0006.000

30.00013.5008.700

25.0008.0004.500

24.0009.000

10.0004.500

11.50024.0001.500

References


DuPontDuPekLan FaYKKBrilenNilitLan FaDuPontTWDVal LesinaSTPC

NilitGlanzstoff BohemiaSTPCBarmagSASAIndoramaNilitSTPCTen Cate

GermanyMexicoTaiwanUSASpainIsraelTaiwanGreat BritainGermanyItalyIran

IsraelCzech Republic

IranBelarusTurkeyIndiaIsraelIranNetherlands

Automatic BCF storage/packing systemFully automatic spinning plantAutomatic DTY packing systemAutomatic POY doffing systemAutomatic POY doffing/packing systemAutomatic POY doffing systemFully automatic texturing (AFK) plantFully automatic spinning plantFully automatic spinning plantAutomatic POY/DTY packing systemFully automatic spinning plant incl. automatic pallet & bale warehousing

Tail turning stationInspection loop

Fully automatic bale transportAutomatic POY doffing systemFully automatic spinning plantAutomatic POY doffing/packing systemAutomatic POY doffing systemExtensionTransport, packing & warehousing system

26.00028.00030.0001.5001.5003.200

60.0006.0007.0006.000

15.000

6.0007.000

6.0009.000

30.0005.000

15.000

References


TechnopartnersNoyfilTechnofibresPPGAlsafilLan FaDiolenJulonSlovkordAlok IndustriesZhejiang ShengyuanZhejiang ShengyuanNilitSumeetSanathanWellknownLiaoning LongqiwanYiwu HuadingYiwu HuadingFujian Jingfeng

NetherlandsSwitzerlandLuxemburgGreat BritainItalyChinaGermanySloweniaSlovakiaIndiaChinaChinaIsraelIndiaIndiaIndiaChinaChinaChinaChina

Artificial grass bobbin handlingPOY/DTY automation systemAutomatic POY doffing/packing systemGlass fibre bobbin handlingFully automatic texturing plant (MPS)Fully automatic texturing plant (AFK)Technical yarn automation systemFully automatic POY plantFully automatic technical yarn plantAutomatic POY/FDY doffing & packingFully automatic FDY plantAutomatic POY doffing systemAutomatic POY doffing systemAutomatic POY/FDY doffing systemAutomatic POY/FDY doffing & packingAutomatic POY/FDY doffing & packingFully automatic POY/FDY plantFully automatic POY/FDY plantAutomatic DTY packing system Fully automatic POY/HOY plant

15.00012.0005.0001.0006.500

30.0003.0007.5004.500

115.000150.00025.0001.000

20.00065.00070.000

100.00060.00030.00020.000

References

Main advantages for automation :

• Increase of product quality (No-touch Yarn)

• Labor reduction (higher independence from

workforce)

• Higher flexibility (no mixing of products)• Precise and repeatable packing uniformity• Higher yarn price due to constant

documented quality operation

• Two different types of filament automation :

– Semi-automatic solution still considering

some manual operational support. (e.g.

creel cart handling)

– Full-automation even including automatic

buffer system for product accumulation

with nearly none manual assist.

Semi-automatic solution (Animation)

Simulation of complete automationsystems prior detailed design:

• all physical parameters of a machine arebeing considered in a model (e.g. speed, acceleration, deceleration, weight …)

• Quantities of equipment, distances andproduction data is considered

• Results leads to conceptional improvementsand optimum final layout.

• Software can be tested prior site installation.

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