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The Future of BCF Technology

With the introduction of the rotating tangle unit RoTac3 at Domotex 2015, the Oerlikon Segment Manmade Fibers wants to pave the innovative way to the future of BCF technology. Oerlikon Neumag’s exhibition highlight enables substantial energy savings and creates many further advantages for the production of BCF carpet yarn with the 3-end plant S+.

The tangling or intermingling plays a decisive part in the production of BCF yarns. Through the tangle knots, loop formations are prevented when tufting and weaving the carpets. Furthermore, they also define the colour mixtures of tricolor yarns and thus enable a homogenous appearance of so-called tricolor carpets. The constant increase of productivity respectively, the process speeds implicated increasing demands on the tangling, resulting in higher air pressures and a double tangling unit. The compressed air consumption significantly increased. Additionally, so-called tangle dropouts occurred at very high process speeds.

The RoTac tangle unit has been the effective solution for the single-end BCF plant Sytec One since 2012. In the meantime, practically all Sytec Ones are sold with the RoTac. However in order to use this technology for our flagship S+, a considerable amount of detailed work was necessary“, stated Mathias Stündl, Head of BCF Development at Oerlikon Neumag.

RoTac3: A further plus for the S+
The new RoTac3 is perfectly tuned for the 3-end BCF plant S+. In comparison to conventional tangle units, the RoTac technology forms the tangle knots with a pulsating instead of a continuous air current. The core element of the RoTac is a rotating nozzle jacket which has several holes with a corresponding spacing according to the required number of knots. If a hole is positioned over the compressed air opening, an air blast is released and tangles the yarn. Therefore compressed air is only consumed if a tangle knot is to be formed. The necessary volume flow and therefore the energy consumption are significantly reduced. In comparison to conventional tangle units, the compressed air consumption is reduced by up to 50%. Therefore the RoTac3 has been granted the e-save label for particularly energy-efficient and eco-friendly technologies.

This principle enables the RoTac³ to generate tangle knots with defined distances and controllable strengths. Tangle dropouts are reduced and downstreaming performance improved. A very gentle yarn treatment reduces the yarn tension. The resulting, better process stability is very beneficial for future trends such as fine deniers and demanding polymers.

RoTac3 is immediately available for the BCF plant S+ and can be retrofitted in already existing S+ plants.

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