Turnkey Solutions for the Production of BCF Carpet Yarn, Synthetic ...

Turnkey Solutions for the Production of

BCF Carpet Yarn , Synthetic Staple Fiber and

Nonwovens

February 2008

Date: 1 Mai, 2007 Event: Presentation

Products

Staple fiber

BCF carpet yarn

Nonwovens


Neumag: Staple Fiber Plants – for Commodities

Spinning and fiber lines with aproduction capacity of up to 250t/d for a staple fiber productionfrom polyester, polyamide andpolypropylene

… for applications such as

� textile yarns for apparel,� thermobonded

nonwovens, � home textiles or technical

filters and many more …


Speciality market: one and twostep plants with a capacityrange of 12 to 120 t/d for theStaple fiber production

.. for applications such as

� Reeinforcement� Various „bico“ end uses

� Carpet and carpet backings

� Geotextiles� Hygiene

Neumag: Staple Fiber Plants – for Specialities


Products

Staple fiber

BCF carpet yarn

Nonwovens


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


Products

Staple fiber

BCF carpet yarn

Nonwovens


Neumag Nonwoven Technology

KortecFestooning Technology

Neumag Spunbond

Technology

M & J Airlaid

Technology

Fehrer Needling

Technology

AutefaCrosslapping Technology

FORCarding

Technology

J & MMeltblownTechnology


NeumagNeumünsterGermany

AutefaFriedberg Germany

FehrerLinz Austria

FincardeBiella Italy

Neumag Details

• Foundation: 1948 in Neumünster

• Employees: 800

• Turnover: 250 mill. EUR

• Export share: approx. 95%

• Main markets: America, Asia, Europe, Turkey,

Middle East

• Customers: more than 2.300 in over 65 countries


Neumag - Manufacturing

Neumag is your specialist for highly sophisticated manufacturing. The range of competences reach from engineering to assembly.


Engineering

• Binding contract guarantees for the productquality and performance of our plants

• Turnkey project management includes all kinds of demanded engineering services

• Customized engineering solutions


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

Date: 1 Mai, 2007 Event: PresentationPage 13 Corporate Presentation Master

Organizational Structure


PET Bottles PET Flakes

PET Chips

PET Melt

Fiber productionExtrusion

Fiber productionPTA, MEG

Raw Materials


Material for Fiber Production – PET Bottles

• PET bottles (collectingsystems)

• Inhouse bottle-recyclingprocess.

(Quality control of the flakes)

• Supplied flakes. (Qualitydepending on suppliers)


PET Flake Requirements for Spinning

• Flake specification:

• Intrinsic viscosity IV > 0,72• Content of humidity

• Meltable contamination

• Non-meltable contamination• Mechanical properties


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


General Process for Flake Production


Foreign Particle Separation in Bottles

Eddy current separation method

Fully automatic sorting of bottles


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


Staple Fiber Plant: Discontinuous (2-step) process

Spinning

Quenching

Drawing & Crimping

Cutting


Spinning Quenching

Drawing & Crimping

Cutting & Baling

Staple Fiber Plant: Continuous (1-step) process


•Textile yarns for clothing- cotton-type yarns- wool-type yarns- sewing yarns

Fiberfill applications- pillows- blankets- mattresses- soft toys

Nonwovens- filters- geo-textiles- automobile

Final Applications


Bico-Yarn with Low Cost Core

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

… take a mono-polymer yarn and replaceas much „core“ as possible with thecheapest possible polymer = R-PET…


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


Neumag – Product Portfolio


Neumag Spunbond Technology

Lowdpf

Highdpf

Olefin Nonolefin

LowMFR

HighMFR

< 0.7 dpf – > 4 dpf PP, PEPET, PA6PLA etc.

MFR 20 - 350

Quality

Flexibility

Productivity

Spinning speed up to 6000 m/min


Applications Spunbond Nonwoven Lines

• Diapers

• Filtration

• Medical fabrics • Protective clothing

• Agriculture

• Bedding and furniture• Industrial applications

• …


Turnkey airlaid plants for production of latex, thermal or multibonded airlaid products.

Neumag Airlaid Technology


Applications Airlaid Nonwoven Lines

• Wet wipes

• Wet toilet tissues

• Wound care• Napkins and table covers

• Feminine hygiene

• Baby diapers• Adult incontinence

• …


Neumag Carding Nonwoven Technology


Applications Carded Nonwoven Lines

• Geotextiles

• Roofing materials• Automotive

• Artificial leather

• Carpet• Carpet backing

• Paper maker felt

• …


From Bottle Waste to Fiber Bottle inlet

Blending/storage silos

Flake washing

Draw line

Staple fiber outlet in bales

Extrusion and spinningline


Integrated Staple Fiber / Carded Line

Neumag Staple Fiber

Autefa Baling

AutefaCrosslapper

FOR Carding

FehrerNeedlepunching

Thank you for your attention .

Turnkey Solutions for the Production of BCF Carpet Yarn, Synthetic ...

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