Turnkey Solutions for the Production of BCF Carpet Yarn, Synthetic Staple Fiber and Nonwovens. February 2008
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1 Turnkey Solutions for the Production of BCF Carpet Yarn, Synthetic Staple Fiber and Nonwovens February 2008
2 Products Staple fiber BCF carpet yarn Nonwovens Page 2 Date: 1 Mai, 2007 Event: Presentation
3 Neumag: Staple Fiber Plants for Commodities Spinning and fiber lines with a production capacity of up to 250 t/d for a staple fiber production from polyester, polyamide and polypropylene for applications such as textile yarns for apparel, thermobonded nonwovens, home textiles or technical filters and many more Page 3 Date: 1 Mai, 2007 Event: Presentation
4 Neumag: Staple Fiber Plants for Specialities Speciality market: one and two step plants with a capacity range of 12 to 120 t/d for the Staple fiber production.. for applications such as Reeinforcement Various bico end uses Carpet and carpet backings Geotextiles Hygiene Page 4 Date: 1 Mai, 2007 Event: Presentation
5 Products Staple fiber BCF carpet yarn Nonwovens Page 5 Date: 1 Mai, 2007 Event: Presentation
6 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 6 Date: 1 Mai, 2007 Event: Presentation
7 Products Staple fiber BCF carpet yarn Nonwovens Page 7 Date: 1 Mai, 2007 Event: Presentation
8 Neumag Nonwoven Technology FOR Carding Technology Autefa Crosslapping Technology Fehrer Needling Technology Neumag Spunbond Technology J & M Meltblown Technology M & J Airlaid Technology Kortec Festooning Technology Page 8 Date: 1 Mai, 2007 Event: Presentation
9 Neumag Details Neumag Neumünster Germany Foundation: 1948 in Neumünster Employees: 800 Turnover: 250 mill. EUR Export share: approx. 95% Main markets: America, Asia, Europe, Turkey, Autefa Friedberg Germany Middle East Customers: more than in over 65 countries Fincarde Biella Italy Fehrer Linz Austria Page 9 Date: 1 Mai, 2007 Event: Presentation
10 Neumag - Manufacturing Neumag is your specialist for highly sophisticated manufacturing. The range of competences reach from engineering to assembly. Page 10 Date: 1 Mai, 2007 Event: Presentation
11 Engineering Binding contract guarantees for the product quality and performance of our plants Turnkey project management includes all kinds of demanded engineering services Customized engineering solutions Page 11 Date: 1 Mai, 2007 Event: Presentation
12 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 12 Date: 1 Mai, 2007 Event: Presentation
13 Organizational Structure Page 13 Date: Corporate 1 Mai, Presentation 2007 Event: Master Presentation
14 Raw Materials PTA, MEG PET Melt Fiber production PET Chips PET Bottles PET Flakes Extrusion Fiber production Page 14 Date: 1 Mai, 2007 Event: Presentation
15 Material for Fiber Production PET Bottles PET bottles (collecting systems) Inhouse bottle-recycling process. (Quality control of the flakes) Supplied flakes. (Quality depending on suppliers) Page 15 Date: 1 Mai, 2007 Event: Presentation
16 PET Flake Requirements for Spinning Flake specification: Intrinsic viscosity IV > 0,72 Content of humidity Meltable contamination Non-meltable contamination Mechanical properties Page 16 Date: 1 Mai, 2007 Event: Presentation
17 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 17 Date: 1 Mai, 2007 Event: Presentation
18 General Process for Flake Production Page 18 Date: 1 Mai, 2007 Event: Presentation
19 Foreign Particle Separation in Bottles Eddy current separation method Fully automatic sorting of bottles Page 19 Date: 1 Mai, 2007 Event: Presentation
20 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 20 Date: 1 Mai, 2007 Event: Presentation
21 Staple Fiber Plant: Discontinuous (2-step) process Spinning Quenching Drawing & Crimping Cutting Page 21 Date: 1 Mai, 2007 Event: Presentation
22 Staple Fiber Plant: Continuous (1-step) process Spinning Quenching Cutting & Baling Drawing & Crimping Page 22 Date: 1 Mai, 2007 Event: Presentation
23 Final Applications Textile yarns for clothing - cotton-type yarns - wool-type yarns - sewing yarns Fiberfill applications - pillows - blankets - mattresses - soft toys Nonwovens - filters - geo-textiles - automobile Page 23 Date: 1 Mai, 2007 Event: Presentation
24 Bico-Yarn with Low Cost Core take a mono-polymer yarn and replace as much core as possible with the cheapest possible polymer = R-PET 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 Page 24 Date: 1 Mai, 2007 Event: Presentation
25 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 25 Date: 1 Mai, 2007 Event: Presentation
26 Neumag Product Portfolio Page 26 Date: 1 Mai, 2007 Event: Presentation
27 Neumag Spunbond Technology Productivity Quality Spinning speed up to 6000 m/min Flexibility Low dpf High dpf Olefin Non olefin Low MFR High MFR < 0.7 dpf > 4 dpf PP, PE PET, PA6 PLA etc. MFR Page 27 Date: 1 Mai, 2007 Event: Presentation
28 Applications Spunbond Nonwoven Lines Diapers Filtration Medical fabrics Protective clothing Agriculture Bedding and furniture Industrial applications Page 28 Date: 1 Mai, 2007 Event: Presentation
29 Neumag Airlaid Technology Turnkey airlaid plants for production of latex, thermal or multi bonded airlaid products. Page 29 Date: 1 Mai, 2007 Event: Presentation
30 Applications Airlaid Nonwoven Lines Wet wipes Wet toilet tissues Wound care Napkins and table covers Feminine hygiene Baby diapers Adult incontinence Page 30 Date: 1 Mai, 2007 Event: Presentation
31 Neumag Carding Nonwoven Technology Page 31 Date: 1 Mai, 2007 Event: Presentation
32 Applications Carded Nonwoven Lines Geotextiles Roofing materials Automotive Artificial leather Carpet Carpet backing Paper maker felt Page 32 Date: 1 Mai, 2007 Event: Presentation
33 From Bottle Waste to Fiber Draw line Extrusion and spinning line Blending/storage silos Bottle inlet Flake washing Staple fiber outlet in bales Page 33 Date: 1 Mai, 2007 Event: Presentation
34 Integrated Staple Fiber / Carded Line Neumag Staple Fiber Autefa Baling Fehrer Needlepunching FOR Carding Autefa Crosslapper Page 34 Date: 1 Mai, 2007 Event: Presentation
35 Thank you for your attention.
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