turnkey solutions for the production of bcf carpet yarn, synthetic
TRANSCRIPT
Turnkey Solutions for the Production of
BCF Carpet Yarn , Synthetic Staple Fiber and
Nonwovens
February 2008
Page 2 Date: 1 Mai, 2007 Event: Presentation
Products
Staple fiber
BCF carpet yarn
Nonwovens
Page 3 Date: 1 Mai, 2007 Event: Presentation
Neumag: Staple Fiber Plants – for Commodities
Spinning and fiber lines with aproduction capacity of up to 250t/d for a staple fiber productionfrom polyester, polyamide andpolypropylene
… for applications such as
� textile yarns for apparel,� thermobonded
nonwovens, � home textiles or technical
filters and many more …
Page 4 Date: 1 Mai, 2007 Event: Presentation
Speciality market: one and twostep plants with a capacityrange of 12 to 120 t/d for theStaple fiber production
.. for applications such as
� Reeinforcement� Various „bico“ end uses
� Carpet and carpet backings
� Geotextiles� Hygiene
Neumag: Staple Fiber Plants – for Specialities
Page 5 Date: 1 Mai, 2007 Event: Presentation
Products
Staple fiber
BCF carpet yarn
Nonwovens
Page 6 Date: 1 Mai, 2007 Event: Presentation
Neumag BCF Product Family
Turnkey plant for small and large scale production
� 2 positions & more
� 1,2 and 3-end winder
� Single and multicolour
� PP, PP/PA6, PA6, PA66, PET
� Several texturizing options
Page 7 Date: 1 Mai, 2007 Event: Presentation
Products
Staple fiber
BCF carpet yarn
Nonwovens
Page 8 Date: 1 Mai, 2007 Event: Presentation
Neumag Nonwoven Technology
KortecFestooning Technology
Neumag Spunbond
Technology
M & J Airlaid
Technology
Fehrer Needling
Technology
AutefaCrosslapping Technology
FORCarding
Technology
J & MMeltblownTechnology
Page 9 Date: 1 Mai, 2007 Event: Presentation
NeumagNeumünsterGermany
AutefaFriedberg Germany
FehrerLinz Austria
FincardeBiella Italy
Neumag Details
• Foundation: 1948 in Neumünster
• Employees: 800
• Turnover: 250 mill. EUR
• Export share: approx. 95%
• Main markets: America, Asia, Europe, Turkey,
Middle East
• Customers: more than 2.300 in over 65 countries
Page 10 Date: 1 Mai, 2007 Event: Presentation
Neumag - Manufacturing
Neumag is your specialist for highly sophisticated manufacturing. The range of competences reach from engineering to assembly.
Page 11 Date: 1 Mai, 2007 Event: Presentation
Engineering
• Binding contract guarantees for the productquality and performance of our plants
• Turnkey project management includes all kinds of demanded engineering services
• Customized engineering solutions
Page 12 Date: 1 Mai, 2007 Event: Presentation
Neumag R&D Centers� Neumünster/Germany:
- BCF and Staple Fiber - Spundbond Technology- Festooning Technology- Carpet Competence Center
� Linz/Austria:- Carding Technology
� Dawsonville/USA- Spunbond/Meltblown
Page 13 Date: 1 Mai, 2007 Event: PresentationPage 13 Corporate Presentation Master
Organizational Structure
Page 14 Date: 1 Mai, 2007 Event: Presentation
PET Bottles PET Flakes
PET Chips
PET Melt
Fiber productionExtrusion
Fiber productionPTA, MEG
Raw Materials
Page 15 Date: 1 Mai, 2007 Event: Presentation
Material for Fiber Production – PET Bottles
• PET bottles (collectingsystems)
• Inhouse bottle-recyclingprocess.
(Quality control of the flakes)
• Supplied flakes. (Qualitydepending on suppliers)
Page 16 Date: 1 Mai, 2007 Event: Presentation
PET Flake Requirements for Spinning
• Flake specification:
• Intrinsic viscosity IV > 0,72• Content of humidity
• Meltable contamination
• Non-meltable contamination• Mechanical properties
Page 17 Date: 1 Mai, 2007 Event: Presentation
Contamination in R-PET
Different polymers
• Polyvinylchloride PVC
• Silicone und rubber
• Polyolefins
• Polyamide
• coloured PET
Other contamination
• Cellulose fibers
• Glue
• Ink
• Metal
• Rest of liquids
• Dust
Page 18 Date: 1 Mai, 2007 Event: Presentation
General Process for Flake Production
Page 19 Date: 1 Mai, 2007 Event: Presentation
Foreign Particle Separation in Bottles
Eddy current separation method
Fully automatic sorting of bottles
Page 20 Date: 1 Mai, 2007 Event: Presentation
Foreign Particle Separation in Flakes
Sink-float method Fully automatic flake sorter
1 Conveying chute
2 Metal detector
3 Light source
4 Line scan camera
5 Image processing
6 Blow-out system
7 Valve control
8 PET
9 Foreign particles
Page 21 Date: 1 Mai, 2007 Event: Presentation
Staple Fiber Plant: Discontinuous (2-step) process
Spinning
Quenching
Drawing & Crimping
Cutting
Page 22 Date: 1 Mai, 2007 Event: Presentation
Spinning Quenching
Drawing & Crimping
Cutting & Baling
Staple Fiber Plant: Continuous (1-step) process
Page 23 Date: 1 Mai, 2007 Event: Presentation
•Textile yarns for clothing- cotton-type yarns- wool-type yarns- sewing yarns
Fiberfill applications- pillows- blankets- mattresses- soft toys
Nonwovens- filters- geo-textiles- automobile
Final Applications
Page 24 Date: 1 Mai, 2007 Event: Presentation
Bico-Yarn with Low Cost Core
for example:
BCF yarn with a high performance sheath and a low cost core:
- 10% higher investment
+ 35% reduced raw material costs
+ 60% reduced raw material costs for R-PET core
+ Fancy look for cut pile
… take a mono-polymer yarn and replaceas much „core“ as possible with thecheapest possible polymer = R-PET…
Page 25 Date: 1 Mai, 2007 Event: Presentation
SYTEC ONE: Single-End BCF Technology
Single-end means one yarn end BCF per position:
-one spinneret
-one spinning pump
-one quench cabinet
-one texturing system
and one winder
�Perfect yarn path
�Higher efficiency
�Higher flexibility
Page 26 Date: 1 Mai, 2007 Event: Presentation
Neumag – Product Portfolio
Page 27 Date: 1 Mai, 2007 Event: Presentation
Neumag Spunbond Technology
Lowdpf
Highdpf
Olefin Nonolefin
LowMFR
HighMFR
< 0.7 dpf – > 4 dpf PP, PEPET, PA6PLA etc.
MFR 20 - 350
Quality
Flexibility
Productivity
Spinning speed up to 6000 m/min
Page 28 Date: 1 Mai, 2007 Event: Presentation
Applications Spunbond Nonwoven Lines
• Diapers
• Filtration
• Medical fabrics • Protective clothing
• Agriculture
• Bedding and furniture• Industrial applications
• …
Page 29 Date: 1 Mai, 2007 Event: Presentation
Turnkey airlaid plants for production of latex, thermal or multibonded airlaid products.
Neumag Airlaid Technology
Page 30 Date: 1 Mai, 2007 Event: Presentation
Applications Airlaid Nonwoven Lines
• Wet wipes
• Wet toilet tissues
• Wound care• Napkins and table covers
• Feminine hygiene
• Baby diapers• Adult incontinence
• …
Page 31 Date: 1 Mai, 2007 Event: Presentation
Neumag Carding Nonwoven Technology
Page 32 Date: 1 Mai, 2007 Event: Presentation
Applications Carded Nonwoven Lines
• Geotextiles
• Roofing materials• Automotive
• Artificial leather
• Carpet• Carpet backing
• Paper maker felt
• …
Page 33 Date: 1 Mai, 2007 Event: Presentation
From Bottle Waste to Fiber Bottle inlet
Blending/storage silos
Flake washing
Draw line
Staple fiber outlet in bales
Extrusion and spinningline
Page 34 Date: 1 Mai, 2007 Event: Presentation
Integrated Staple Fiber / Carded Line
Neumag Staple Fiber
Autefa Baling
AutefaCrosslapper
FOR Carding
FehrerNeedlepunching
Thank you for your attention .