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It was the highlight at ITMA Asia + CITME last fall: POY 2.0. The new filament yarn spinning concept, which was presented to a select group of customers, met with great interest: several yarn producers spontaneously applied for a pilot plant.
For Barmag's new POY spinning concept, the technologists and engineers at the Remscheid-based innovation hub took a close look at the entire spinning process. And completely revised the concept. Core components were modified in both the spinning and take-up areas to optimize the production process. Where is the journey taking modern POY manufacturers? To greater efficiency, greater ease of use, greater sustainability, and above all, greater control over every single process step.
Core component: the spin pack – small but mighty
In the new generation of the DIO spin pack, the excellent rheological properties typical of this design have been further optimized – guaranteeing absolute uniformity of the filaments. In addition, the new DIO has been made significantly more compact. This means that, with the same filter performance, the requirement for filter sand is reduced by a third and the weight of the component by more than 30%. This makes the spin pack more sustainable in terms of consumables and simplifies its handling for the operator.
The spinning beam also benefits from the more compact spin pack: the spinning beam design has been adapted accordingly. This reduces the surface area of the component, resulting in energy savings of up to 10%.
EvoQuench 2.0 – sustainable and user-friendly
Uniformity is also the decisive factor in quenching. Absolutely identical air conditions for all filament bundles are a must. This has always been a feature of the EvoQuench radial quenching unit. New in version 2.0 is that the convergence length can be adjusted more easily and the adjustment elements are easier to reach. This has a positive effect on handling, setup time, and the amount of waste.
Automated threading with WINGS 2.0
At the heart of the spinning system of the future is WINGS POY 2.0: For the first time, the machine features an automatic string-up function. This feature, long awaited by experts, ensures consistently short string-up times and, as a result, reduced waste production. As a consequence, fewer skilled operators are needed at the take-up level.
The active Quick Returns of the WINGS POY 2.0 make it easier to adjust product-specific settings. This is particularly advantageous for manufacturers who frequently change the yarn product they spin and want to run demanding products. A welcome side effect: no overthrown yarn ends and even better bobbin formation.
Another innovation on the winder is the additional shielding, which effectively and permanently prevents the formation of fluffs. The shielding gently guides the yarn and the air flow and ensures that the yarn stays where it belongs: on the bobbin.
The new yarn end fixation puts an end to loose yarn ends during package handling. During package handling and transport, the yarn ends remain securely attached to the package. Machine downtime due to faulty sensor signals in downstream automated logistics processes caused by loose yarn ends is also a thing of the past. The XPT housing with a larger rotor stroke extends the parking time, making the doffing process more flexible. Another plus in terms of sustainability: the system runs continuously and is even more productive thanks to significantly fewer forced winder stops.
atmos.io
POY 2.0 is fully embedded in the atmos.io system world. This gives plant operators an overview of their production at all times via a variety of useful apps. The entire path of the polymer from melt to yarn is digitally monitored, and operating personnel have insight into the quality parameters at all times and can intervene quickly if necessary. The result is less waste, better product quality, and higher margins thanks to the fully networked factory.
When innovation sets the pace
With POY 2.0, Barmag is sending a strong signal for the future of filament yarn production. The combination of intelligently advanced technology, intuitive usability, and consistent digitalization creates a production environment that is more reliable, resource-efficient, and powerful than ever before.
For yarn manufacturers, this means a clear competitive advantage in a demanding market – and the certainty of working with a solution that is ready for tomorrow's challenges. POY 2.0 is more than just a new spinning concept. It is the next step into a new era of efficiency.