Into the heart of the machine

Posted by on set 28, 2011 in ITMA | 0 comments

A visit to the Oerlikon’s Virtual Showroom in Hall 2 is well worth making for a complete overview of the extrusion spinning process.

The company’s extraordinary 3D graphics can take you right into the heart of the machine, for views it’s not even possible to achieve with the actual machine.

With a 65% market share, Oerlikon Neumag is the leading global supplier of systems for BCF carpet yarn, for example, and its latest S+ brings together all the benefits of previous technologies. Optimisation measures, however, mean production speeds can be dramatically increased.

Finding the niches that huge operations like Oerlikon can’t really fill, meanwhile, is the UK’s Fibre Extrusion Technology (FET).

“We are a provider of bespoke solutions, with know-how in respect of equipment design, process technology and assembly,” says FET managing director Richard Slack. “The fields we work in involve the production of high value materials in low volumes and we work closely in collaboration with both fibre suppliers and manufacturers on research projects, process development and technical feasibility studies and pilot batch production for product trials. This gives us a head start over competitors when projects are ready for successful scale-up, in building the machines and providing on-site installation and commissioning.”

FET also has a track record in the field of bicomponent and tricomponent meltspinning and has also adapted the meltblowing process specifically for biomedical applications. This has led to the production of resorbable nonwovens for the first time and the technology is proving capable of processing other high end polymers for technical and functional nonwoven material applications.

Blue Carbon
A cotton t-shirt can produce up to fifty times its own weight in CO2 emissions, says Italy’s Flainox, a company taking its environmental obligations very seriously.

A commissioned study has shown that the Blue Carbon-certified manufacturer of dyeing machines has halved the CO2 emissions at its Biella manufacturing plant over a one-year period, representing a 29% CO2e reduction per kg of fabric eventually produced on its machines and $1.6 million in savings over a 15-year period.

In addition, the carbon footprint of the company’s latest Universal NRG dyeing machine over a life cycle of 15 years has been shown to reduce CO2 emissions by 35%, translating to a cost reduction of $2.4 million over a 15-year usage period. The machine pictured here has been sold to Brazilian company Lupo.

Water and energy savings are also the keys to Xorella’s latest range of EnviroTec steaming and conditioning solutions.

Conditioning and steaming machines of all makes commonly use vacuum pumps based on the old fashioned water ring technology to evacuate air and steam from their vessels.

The various vacuum cycles which have to be conducted make the use of water for cooling and sealing them an important cost factor.

Xorella’s XO-EcoPac employs a water-free vacuum system is on a high tech, low consumption dry vacuum pump, demanding less than half the installed power of conventional water ring pumps.

There is usually an enormous amount of water wasted in a conditioning process and in respect of high temperature steaming for heat-setting it’s even higher, due to the fact that more steam has to be evacuated and a final vacuum for drying purposes is carried out.

XO-EcoPac saves 100% of cooling water which can lead to huge economical savings throughout the year.

Finally a mention for a new company CU4motion, which has developed a fully automatic needle exchanger based on sophisticated software. It is capable of scanning needleboards and replacing the needles anywhere this is required, as well as the storage of needle bed designs and the optimisation of needling patterns. In needlepunching, the replacement of needless is an extremely time consuming job, not to mention costly, so CU4motion’s system will meet a real need in the industry.

source: ITMA

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