Barmag, MAE Melt spinning line 24Y

stopped as the factory was closed
Composed of:
*4 automatic winders Barmag Mod. ASW1208,
*1 system of the granulated polymer unloading and conveyance,
*1 inverter,
*1 stress - stain test instrument Mod. MESDAN,
* set of laboratory instruments: 1 analytical scale Mod. 90BMARK 120A; 1 anemometer Mod.
Accuracy 0,1m/s; 1 stroboscope Pico 331; 1 electronic Thermometer Noronix HI 93530
* Electronic board,
* Spinnerets 36,72,144 round holes,
* Press for spin pack assembly, 2011 YOC
* all other new spare parts related to the line.
On Mae it can be produced only POY yarn

We was bouhght it only for virginchips. Maybe it is needed something to add and use it qith recycled chips.
The line was stopped at 2014. It is almost new. And many spare parts and additional instruments never used.

More technical information:



1.0 INTRODUCTION

MORODER POY lines, compact and simple, are designed for a cost effective production POY for textile applications.
Thanks to the use of the most up-to-date technologies, equipment by MORODER can meet all the quality and efficiency related specifications.
An extensive use of the most advanced and reliable electronic systems allows to reach a high accuracy in the control of all parameters and to properly monitor equipment behaviour.
Design based on actual user’s needs, strong construction and quality of components result in highly reliable equipment showing long working life and low maintenance.
The here offered equipment can be split in the following sections.



1.1 POLYMER CHIP FEEDING

Feeding of polymer chips and dosing of master batch / additives are automatically carried out, directly on the operative plant.

PET polymers are processed trough a dryer and crystallizer



1.2 EXTRUSION

Extruder, fed by the unit described in the previous section, is equipped with AC motors that, through reducer, drives extruder screw. Melt pressure is accurately controlled by means of sophisticated electronic systems which act on inverter controlling extruder screw motor.



1.3 SPINNING

Spinning heads, insulated in a proper way, are filled with diathermal oil vapours provided by a separate boiler with relevant piping and security valves.
Spinning heads house spinning pumps and spinning packs including melt distributors, pressure breakers, filtering screens and spinnerets new concept spinning pack allows long life.
First quality volumetric metering pumps specially designed for spinning are used; they are driven by synchronous AC motors controlled by inverters.



1.4 FILAMENT QUENCHING

Extruded and spun filaments are quenched in chambers fed by a laminar flow of conditioned air.
Quenching air is treated in suitable units provided with chilled air and fed to each chamber; a laminar flow of air comes out through chamber filters which ensure high distribution uniformity.




1.5 WINDING (TAKE-UP)

The drawn yarn is wound on cylindrical bobbins by automatic doffing winders .




1.6 CONTROLS

MORODER use the most advanced architectures suitable for the real industrial environments.
All standard FDY plants are conveniently operated through computer based supervisory systems, where all parameter setting, reading, alarm management, etc. are centralised; however, all process entities (temperatures, pressures, speeds) are actually controlled by dedicated intelligent units very close to the field, resulting in fast and highly reliable control loops.

Temperatures and Polymer Pressures:
Temperatures and polymer pressures are controlled by digital PID instruments.

Polymer pressure control loops act on extruder motor speeds through control drives.

Motors:
High-tech digital inverters are used for controlling synchronous AC motors and asynchronous AC motors.
Thanks to the most advanced digital inverters, a very high speed accuracy is achieved.
The performances of asynchronous AC motors controlled by such inverters are comparable to the ones of synchronous AC motors.

Doffing cycles are controlled by dedicated PLC.

Communications between the computers and the many intelligent controllers (themoregulators, inverters, etc.) are digitally performed by suitable serial lines. The above mentioned computer based supervisory systems provide production operators/ supervisors and maintenance technicians with a simple/safe interface and tools for an easy plant run.


2.1 PRODUCTS

PET POY YARN

FINAL YARN COUNT
(den) (*)

N°. OF INSTALLED YARN
OUTPUT
(Kg/h)
“average”
250/72-96
24
230





FILAMENT COUNT RANGE :
As per the installed spinnerets
FILAMENT CROSS SECTION :

round






IMPORTANT NOTICE

(*) THE POY COUNT IS THE YARN THAT, AFTER DRAW-TEXTURIZING( WITH DRAW RATIO 1:1,69), REACHS THE FINAL REQUESTED COUNT.




These figures are guaranteed if the following conditions are respected:

only raw materials suggested by MORODER are used
suitable utilities are available
skilled personnel runs production
production room temperature 20 to 30 °C
production room relative humidity 60 to 80%







2.2 PLANT FEATURES


Extruders:
1

Screw diameter
90 mm

Screw L/D
25




Spinning heads:
3 individually heated by dowtherm oil with boiler




Spinning pumps:
3

Capacity
8 x 8 cc/rev each pump




Spinning positions:
3




Spinning packs:
24 with sand filtration




Spinnerets:
24




Winders
4 BARMAG ASW 1208 automatic winders




























3
PRICES

STANDARD SUPPLY:

1 MAIN PLANT CHALLENGE PET POY MOD. 24Y complete with Computer based supervisory system, double set of spinning packs.

QUENCH AIR SUPPLY WITH HUMIDITY CONTROL

3 BARMAG ASW 1208 AUTOMATIC WINDERS

CONSUMABLE ITEMS (see list at § 5, point H).

TECHNICAL SERVICE AND TRAINING TO PERSONNEL
ELECTRICAL AND MECHANICAL ENGINEERS, PROCESS ENGINEER

TECHNOLOGICAL KNOW-HOW TRANSFER

SET OF SPARE PARTS (list to be defined later)



LIST OF THE PARTS INCLUDED IN THE STANDARD SUPPLY




A) EXTRUSION AND SPINNING


1
PET chips pneumatic conveying system( part of the chips preparation)
1
Extruders 90 diam. Mm. L/D = 25 complete with dynamic mixers.
1
AC motors (45 kW, inverter controlled)
2
Pressure probes DYNISCO
3
Static mixers
3
Spinning heads
3
Spinning pumps of 8 x 8 cc/rev.
3
Spinning pump drives equipped with AC synchronous motors
48
(= 2 sets of 24 pieces) Spinning blocks with sand filtration




B) FILAMENT QUENCHING


1
Air treatment units (serving the chambers mentioned here below)
3
Filament quenching chambers
3
Spinning “chimneys”




C) SPIN-FINISHING


1
On-board spin-finish tank
3
Spin-finish oil dosing / application assemblies (8 ends/each)
3
Units for spin-finish distribution enhancing
3
Sucking assemblies
2
Manually operated yarn aspiration guns






D) WINDING

3
BARMAG ASW 1208 automatic winders


E) ELECTRIC AND ELECTRONIC CONTROL BOARDS

Digital inverters for motors of:

Extruder
Spinning pumps
Winders spindles
Winders traverses

Electronic devices for motors of spin-finish oil dosing pumps

Digital PID microprocessors for temperature regulation: extruder zones, spinning heads .

Computer based supervisory system.
Electric/Electronic minor components, wiring, communication lines, raceways.

ALL THE ELECTRICAL EQUIPMENT FOLLOWS IEC 204.1 STANDARDS


F) MAIN SUPPORTING FRAME AND PLATFORMS
FRAMES FOR DRAWING AND WIRING MODULES, STAIRS

Made with fabricated steel.


G) EXHAUST FUME ASPIRATION SYSTEM FOR PET

3
Suction cope under the spinnerets


H) CONSUMABLE ITEMS

1
Set of 240 pieces of filter nets and gaskets for spin pack assembly.
5
Kg. filtering sand for spinning packs


I) CHILLER

The proposed chiller is sized on the requirements of the quenching chambers air treatment unit. The compressor based refrigeration circuit includes an air cooled condenser and an humidity control
Depending on summer and winter project conditions (temperature and relative humidity), a bigger chiller could be required; exact size of chiller will be defined according to actual needs.

OPTIONS


POLYMER DRYER AND CRYSTALLIZER ( max. capacity 300Kg/h)

The system includes:
Crystallizing hopper
Hot air dryer
System components
Dehumidifying Dryer
Dehumidifying hopper for PET crystallized granule
System components
Conveying system between crystallizing ,drying hoppers and extruder
Vacuum unit with 3 vacuum receivers
Stainless steel residence hopper
Piping
Electrical board



LABORATORY INSTRUMENTS

List of suggested instruments:
Anemometer Mod. Accuracy 0,1m/s
Digital tachometer “ Concor CT 6L
Stroboscope “ Pico 331
Electronic Thermometer “ Noronix HI 93530
AnalogicTensiometer “ 0-250 gr.
Electronic reel “ Lab. 161M
Roman scale “ 163 R
Dynamometer “ Tensolab 10/168C
Analitical scale “ 90BMARK 120A
Binocular microscope “ Campus 191D
Refractometer “ RF 232
Press for spin packs assembly and sand blasting device


AUXILIARIES

List of suggested items :

- Preheating oven (temp. 450 °C) Mod. MAPIS MPS/70



Spinnerets cleaning:


- by resistance heated oven Mod. MAPIS MPS/70 Super
- ultrasound bath Mod. STIMIN ST 40


SET OF OPERATION TOOLS ( INCLUDED IN THE SUPPLY)

SPINNERETS

N° 48 ( 2 sets of 24 pieces) Spinnerets at 72 round holes
N° 48 ( 2 sets of 24 pieces) Spinnerets at 96 round holes


CHILLER WITH HUMIDITY CONTROL ( INCLUDED IN THE SUPPLY)



SET OF SPARE ( INCLUDED IN THE SUPPLY FOR THE MENTIONED AMOUNT)
Extra items to be defined and quoted under request

7
PARTS INCLUDED IN THE STANDARD SUPPLY – TECHNICAL DETAILS


A) EXTRUSION AND SPINNING

1
Extruder 90

Main features:

Asynchronous AC motor

Vibration dampling reducer

Holding structure

Feeding opening with water circulation cooling

Nitrided screw complete with dynamic mixer)

Five armoured heaters (1 for each heating zone along the extruder barrel)

Five cooling fans, set under the heating zones, to prevent further overheating phenomena due to the melted material

Five probes for the temperature control


TECHNICAL DATA OF EACH EXTRUDER:

Screw diameter
90 mm

Screw extruder length (25 diam.)
2250 mm

Heating zones
5

Heating and cooling zones
5

Total electric heating power
32.5 kW

Electric power of the fan
5 x 0.12 kW

Electric power of the extruder motor
45 kW

3
Spinning heads

Main features:

Closed structure made with high tensile steel, tested the high pressures.
Distribution of the melt polymer (equal aging time paths to all spinning packs).

8 spinning housings/each, in which are inserted the spinning packs and to which are fixed the spinning pumps.

Heating provided by separate oil boiler.

Diathermic oil, suitable for the homogeneous distribution of the temperature.

Three probes for temperature monitoring, inserted in the spinning blocks

Static mixer, inserted in the main duct, suitable to homogenize the melt polymer


TECHNICAL DATA:

Heating electric power for dowtherm boiler
50 kW


3
Spinning pump assemblies

including:

3 Synchronous AC motors

3 Reduction gears

3 shaft-clutch driving spinning pumps (safety pin included)

3 spinning pumps (with 1 feeding inlet and 8 outlet deliveries)


TECHNICAL DATA OF EACH ASSEMBLY:

Motor electric power
4.5 kW


Pump’s volumetric capacity
8 x 8 cc/rev.

48
(= 2 sets of 24 pieces) Spinning blocks


B) FILAMENT QUENCHING

1
Air treatment unit (serving the chambers below described)

Main features for each assembly:

Humidity control

Cool water three ways motorised valve

Air distributor with load loss by acrylic screen

1 asynchronous AC motor-fan

1 inverter for fan motor control
PT 100 probes for air temperature control

Electronic thermo regulator for air temperature adjustment


TECHNICAL DATA:

Motor fans air delivery
9.000 m3/h

Refrigeration capacity
95.000 frig/h

Installed electric power
40 kW

Useful air pressure
180 mmH2O




3
Filament quenching chambers

Main features:

Air feeding ducts to the distribution chamber

Air filter

Distributor

Honey-comb equalizer of the air flow with pressurizing nets

Front dimensions
1200 x 1,800 mm


C) SPIN-FINISHING, DRAWING

1
Spin-finish oil tank

Spin-finish oil is stocked in one stainless steel tank.

Set on the high part, which allows to feed spin-finish metering pumps at a constant head.


TECHNICAL DATA:

Volume of the tank
20 I

Pump electric absorption
0.3 kW

3
Spin-finish oil dosing / application assemblies
Including:

3 Electronically speed variable AC motor
3 Volumetric pump capacity 8 x 0,2 cc/rev
3 Sets of oil applicators



D) WINDING

3
Winders
BARMAG ASW 1208

Speed range m/min
1500 – 5000

Bobbins #
8 per winder

Winding traverse stroke mm
120

Bobbin max. diameter mm
420


8
PLANT PERFORMANCES AND YARN CHARACTERISTICS


Outputs at the various yarn counts as per table at § 2 point 2.1
+/- 10%
Full bobbin production
> 95 %


PET POY YARN quality:

Yarn count variation( deviation from daily adjusted spinning count)
+/- 0,5 %
Elongation ( deviation from daily adjusted mean elongation)
+/- 4,0%
Tenacity on raw white
 2 gr/den
Filament cross section
round


PET POY+DTY FINAL YARN (*)

Tenacity

Elongation

Crimp

Shrinkage

Interlacing point



Raw material typical consumption for 1 Kg. of FDY:

Polymer chips
1.04 kg
Finish-oil
0.01 kg
Electrical power consumption
0,65 kW

(*) THOSE FIGURES WILL BE PROVIDED BY THE SUPPLIER OF THE DRAW-TEXTURING EQUIPMENTS

These plant performances, yarn characteristics and raw material consumptions are based and guaranteed if the following conditions are respected:

only raw materials suggested by MORODER are used (see § 9);
suitable utilities are available
skilled personnel runs production
no colour changes occur
production room temperature 20 to 30° C
production room relative humidity 60 to 80%.


Also this line can be completed with:
- KAISER air compressor DS170, 13 bar 1990 YOC – 1pcs,
- Air Dryer DRYSTAR HIROSS MDH45A, 1998 YOC,
- Chiller for air cooling at temperature 18-24C°, 2011 YOC – 1pcs
- Resistance heated oven Mod. MAPIS MPS/70 Super, 2011 YOC - 1 pc
- Ultrasound bath Mod. STIMIN ST40, 2011 YOC - 1 pc
- Sand blasting device Mod. EKO Nomika, 2011 YOC - 1 pc