Self-contained fiber production facility with one step capability serving Geotextile and Coated Fibres & Fabrics markets and Automotive safety applications
• 4 spin-draw lines with combined capacity up to 6,500 tons per year
• DIN ISO 9001 & 14001 certification since 1994
• Excellent environmental & Safety performance No reportable events
Area Site: 37,700 sq. m Production facility: 3,100 sq. m
Technology Solid State Polymiration, Extrusion, 1 line => Barmag Technology 3 lines => Rieter Technology Winding => Barmag Technology
Capacity 3 lines 1,200 tons, 1 line 2,400 tons
Raw material PET Chips
Utilities Provided from Third Party (electricity, steam, compressed air, nitrogen, glycol).
1987 - Production of Nylon Tire Cord
1992 - Modified towards production of High Tenacity Polyester Fibers
1993-1998 - Installation of Spin Draw (S/D) Line 4 and Solid-State Polymerization (SSP) - Installation of automatic doffing and packaging systems
1994 - Quality certification DIN ISO 9001 and 14001
1999-2001 - New Winders installed
The process starts with amorphous PET chip delivered by tank truck and unloaded into a storage silo on site. The chip is then dense phase conveyed to a day silo at the top of the plant. This is fed into a hot air heated Buhler pulse bed crystallizer, which raises the crystallinity to about 40%. From here the chip is conveyed to the 4 day hoppers that each feed one of the production lines.
Each line starts with the chip gravity fed from the day hopper into a vertical SSP reactor that is heated with a hot recirculating Nitrogen stream to raise the iv about 0.4 to 0.5 units depending upon the specs for the final product. The chip is then fed into a Barmag single screw extruder, with 5 heated zones. On line 3 there is also a Color master batch system for feeding color pellets at the throat of the extruder. The molten polymer is fed into 2 HTM heated spin beams with 2 positions each ( total of 4 per line). The polymer is pumped with small gear pumps through a spin pack in each position with a spinneret of 64 to 200 holes depending on product. On Line 4, the pumps are twice the capacity of Lines 1-3.The filament is quenched with a gross flow air quench of about 1.8m long then a cooling zone of an additional 5 m. (About 2 m longer on line 4). The filaments are then divided into 2 thread lines ( Lines 1-3), 4 thread lines ( Line 4) and and pass through an intermingler, then finish applicator, then drawn on either Reiter draw machines (Lines 1-3 ) or a Barmag Draw machines ( Line 4) that have 8 electrically heated draw godets and relax godets. Total Draw ratio is anywhere from 1 to 4 depending on product. Draw speed is a max of 1000 m /m. After drawing the filaments are fed to 4 Barmag winders per line (Lines 1-3) or 8 Barmag winders (Line 4).
Full bobbins are removed from the winders with an automated doffing system that services all 4 lines. The removed bobbins are transported by an overhead conveying system to the warehouse where they are inspected and then conveyed to an automated palletizing system. This system places bobbins into trays, then stacks the trays on a pallet. The full Pallets are then passed through an automated strapping system, then an automated shrink wrap station. The final package is then removed by fork truck and stored in the warehouse for shipment.
Utilities, such as compressed air, water, steam, and nitrogen are supplied by the centralized utilities plan on the industrial site. HTM for the spin beams comes from 4 – 150kw electrically heated HTM boilers in the plant.
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