POLYPROPYLENE POY SPINNING PLANT – yoc 2006

88dtex (80den) POY – Production capacity 800 kg/day

SUMMARY

TECNICAL PART pag. 3

1 - INTRODUCTION TO THE PRODUCTIVE PROCESS " 4

2 - DESCRIPTION OF THE SUPPLY " 6

3 - ENGINEERING " 17

TECNICAL PART

1 INTRODUCTION TO THE PRODUCTIVE PROCESS

1.1 - PRODUCTION CAPACITY OF THE PLANT

The plant is composed of 1 line with 4 collecting heads for 6 ends each. The line is
designed for the production of a polypropylene POY multifilament continuous yarn.

The real production of the line, calculated on base of 88dtex (80den) is as follows:

POY COUNT COLLECTION CAPACITY BOBBINS

SPEED
dtex (den) m/min kg/day n°

88 (80) 2500 760 24

88 (80) 2700 820 24
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1.2 - RAW MATERIALS CONSUMPTION (for 1.000 kg of PP yarn)

- Chips : kg 1.030
- Enzyming oil (medium) : kg 10
- Dowtherm : trascurabile

1.3 - PARAMETERS OF YARN

- POY count variation (daily deviation

on the certain count) :± 0,5 %

- POY elongation (daily deviation

On the medium elongation) :± 4,0 %

- Full bobbins
(diameter 400 ± 20 mm) : 93 %

1.4 - UTILITIES SPECIFICATIONS

- Electrical power
- tension : 230/400 V
- frequency : 50 Hz
- totale power installed : 130 kW
- protection : IP51
- input type : THREE-PHASE+NEUTRAL

- Heating fluid : dowtherm A or equivalent

- quantity : about 200 liters

- Compressed Air tools

- plant feeding pressure : 7 bar
- working pressure : 6 bar
- dew point : - 40 °C
- oil absence
- consumption : 0.6 Nmc/h

- Compressed air
- plant feeding pressure : 7 bar
- gun’s working pressare : 10 bar
- dew point : 7 °C
- gun consumption : 250 Nmc/h at 10 bar

2 DESCRIPTION OF THE SUPPLY

SPINNING PLANT

2.1 Polypropylene POY production line with 4 collections of 6 bobbins each. There are included the system of
cheaps/color/additives loading, dosage system and extruder’s feedbox.
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2.1.1 - Extrusion

N° 1 EM-PP-60/30D Horizontal extruder

Composed as follows:
• Support struture
• Polymer’s feeding lined area for cooled water cirulation
• Heat exchanger for cooling oil
• N° 5 areas with armored resistances
• N° 5 PT100 for temperature control
• Nitrided screw, a form for PP, with dynamic mixer
• AC low side motor with cooling impeller
• Polymer pressure probe
• PT100 for head polymer’s temperature control

Technical details:

• Screw diameter : mm 60
• Screw length (30 diameters) : mm 1.800
• Max extrusion capacity : kg/h 60
• Heating areas : n° 5
• Total heating electrical power : kW 22
• Motor power : kW 26.5

N° 1 Polymer’s net glass-type two ways filter

With electrical heating, approx. 10 kW completed with :

• Feeler for extruder polymer pressare regulation

• Insulation

N° 1 Polymer feeding tube

It is designed for feeding of a fused polymer to the spinning head, with an external racket for
heating by means of the dowtherm steam and predisposition for a three-stages static mixer
“SULZER” type, with coupling flanges.

N° 1 Dowtherm steam generator

Working under vacuum in order to get the steam temperature lower than the boiling point of
the dowtherm. It is composed as follows:

• Horizontal high-resistance steel container

• Low power resistances for surface unit, in order to guarantee a long period of
operation.
• Dowtherm oil level indicator
• Magnetic indicator of safety level, which takes off the electrical input from the
heating resistances in case of a low oil level.
• Safety system, comprising a manometer which removes electrical power from the
heating resistances in case of overpressure, a spring safety valve which consents an
external steam discharge.
• Two PT100 which control the temperature of dowtherm steam and liquid
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 • Safety valve, manovacuum gauge and a drainage valve
• ISPESL homologation
• Insulation excluded
• Vacuum pump with a relative adjustment system or a system with Venturi Tube

Technical details:

• Maximum pressure : bar 5

• Maximum temperature : °C 360
• Working pressare : bar 0,6 absolute
• Working temperature : °C 240
• Electrical heating power : kW 36
• Dowtherm quantity : liters 200

2.1.2 - Spinning

N° 4 Spinning head

To obtain a maximum homogeneity of a spinneret packs temperature, the spinning head is

constructed as follows:

• 2 assembled closet structures

• 2 incomes for the dowtherm steam
• 2 outlets for dowtherm condensate
• 6 bottom slots for spinneret packs
• 1 slot for spinning pumps
• 1 PT100 for dowtherm steam temperature control
• 1 slot for polymer pressure feeler at the spinneret packs
• Insulation included
• Fumes aspiration system with extraction impeller

Technical details:

• Sizes : mm 890 length

mm 540 width
mm 520 height

N° 4 Spinning pumps group

Each group includes the following:

• Synchronous AC motor
• Reduction gear
• Pump command thrower with break pin
• Spinning pump with six deliveries

Technical details:

• Motor power : kW 0,75

• Spinning pump capacity : cm3/turn 1.6 x 6

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 N° 24+24 Spinneret packs

Single packs are completed with:

• Main structure
• Circular spinnerets (not included in the quotation and supply)
• Diffusors
• 5 cloths filters, made of AISI 304 stainless steel
• Aluminium gaskets
• Four bolts for pack assembling

Technical details:

• Spinnerets’ diameter : mm 80/87

• Spinneret packs’ sizes : mm 136 length
mm 60 height
mm 110 width

N° 4 Blowing cells

Each cell is composed of the following:

• Adjustment valve with air delivery to the cells

• Pipe fittine air delivery to the cells
• Air filter
• Air flow distributor
• Manometer
• Two doors empty/full to define
• Adjustable only support for oilers thread guides
• Enzyming oil discharge system with on-the-floor container
• n° 6 interlacers (type to define)

Technical details:

• Distribution section sizes : mm 1.800 x 900

• Material : AISI 304 stainless steel

N° 4 Yarn descent channels

Completed with an automatic closing device and controlled by sensors of yarn presence on
bobbins, with two hooks for thread-suction gun attachment.

2.1.3 - Enzyming

N° 1 Double oiling enzyming system

Composed as follows:

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 • 2 distribution stainless steel tanks with floating level (one for every two spinning
heads)
• 8 enzyming oil dosage pumps (two for each collecting position)
• 8 complete motors e transmissions for enzyming pumps control
• 12 thread-guides oilers, with a possibility of a vertical adjustment (for each
collecting position).

Technical details:

• Distribution tank’s volume : dm3 50

• Motor power : kW 0,04
• Enzyming pumps capacity : cm3/turn 0,12 x 6

2.1.4 - Collection

N° 1 Collection section with 4 winders

The collection section is composed of:

• 8 cold motorized godets, length to be defined on the base of the length of the
mandrels of the winding machines, ∅ 150mm.

• 1 support carpentry for cold godets and winding machines, with epoxidic protection
painting.

BARMAG automatic winders model ASW 1206

Technical details of winding machines:

• Bobbins number : 6
• Maximum mechanical speed : 3.500 m/min
• Maximum bobbins diameter : 420 mm
• Tube length : 200 mm
• Bobbin’s volume : 21,5 dm3
• Mandrel diameter : 110 mm
• Mandrel length : 1200 mm
• Winding traverse : 170 mm
• Minimum count : 60 den
• Two motorized mandrels
• Bobbins expulsion device
• Anti-wrap sensor
• Automatic system of thread-throwing and thread reserve formation
• timer for winding time set up
• traverse vertex with thread sensors (Barmag)
• supervision system (Barmag)
• operating and maintenance instructions (Barmag)

2.1.5 - Electrical-electronic control system for POY spinning line

N° 1 digital inverter for extruder’s AC motor control

N° 4 digital inverters for synchronous motors of the pumps of spinning

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 N° 8 digital inverters for asynchronous motors of the enzyming pumps

N° 1 temperature regulation system

N° 8 digital inverters for synchronous motors of the godets completed with braking resistances

N° 1 Set of boards containing inverters, relative control swithes and all necessary electrical protections

N° 1 Set of boards containing static groups for temperature control (the extruder’s heating areas,
dowtherm heating)

N° 1 industrial PC for the line management, for the polymer’s pressure control at the exit of the
extruder and for the temperature control.
On the PC will be installed a software for management of the sequences and regulations and a
software for the supervision.

2.1.6 - Control software for spinning plants.

General description of the automation system.

The system is composed of a hardware/software package which adopts an innovative philosophy and perfectly
embraces all new technologies which could be applicated in the field of industrial automation and process
control, as well as in the reliability and standardization of products, using commercial equipment.

PLC details.

The software section dedicated to the control of the plant is developed with a Beckhoff TwinCat, a Soft Logic
package, which taking an advantage of a sturdy Real Time module, emulates a powerful PLC in Windows
2000 Pro / XP Pro environment, which represents an international reference point in the industrial automation
sector.
TwinCat supports all IEC 61131-3 programming languages, as well as a quick and effectual compiler which
permits a comfortable and modular programming; in fact the software unites perfectly the tipical characteristics
of the PLC with advantages of an object-oriented programming.
The debug means, offered by the TwinCat should not be underrated, as they permit even a total execution and
therefore the verification of the applications even without the peripherical (I/O unit).
Even regarding the communication with HMI display systems, the TwinCat is able to support the most modern
COM based software interfaces.
In fact a ADS-OCX, a ADS-DLL and the OPC Client/Server mechanism, consent to any high-level language
programm to access TwinCAT variables and functions.
The above mentioned characteristics make the system extremely open towards the external world as for the
high-level communications (network connections, remote assistance etc.), such as for the low-level
communications (connection by fieldbus with new equipment).

2.1.7 - ASPIRATION SYSTEM FOR THREAD THROWING

For the winding area it is designed an aspiration system with 2 thread-sucting guns and
with a mobile can for wastes

2.1.8 - ZINK PLATED SUPPORT CARPENTRY

Completed with stairs and support planes of all machinery:

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 • extruder
• spinning head
• command groups for pumps of spinning
• blowing cells
• electrical boards

2.1.9 - CONDITIONING PLANT RC Conditioners

The conditioning plant is calculated for the optimal cooling of the polymer inside the blowing cell with
controlled thermohydrometrical conditions.

Flow rate = 10.000 m3/h

Temperature= 15-20 °C ±1 °C
Relative humidity = 65-70 % ±5 %

The capacity of the refrigerating group is 70 kW for working with water at 7/12°C. The plant is
completed with the air pressure feeler and with exit filters.

2.2.0 - DOSAGE PLANT polymer colors and additives MOTAN

The dosage plant is designed to feed the plant and it is situated at the mouth of the extruder. It is
composed of 3 sections, one of them for a virgin Polymer and two stations for colors and/or additives.
The plant is completed with feeders exhausters with a tube drawing.

3 ENGINEERING

- The following documentation will be supplied:

- Lay-out of the plant
- Assembly drawings
- Production process description and operating manual
- Wiring diagrams
- Foundation details for all machinery
- Air conditioning distribution plant project
- Guarantee of regularity and homogeneity on the whole surface of the blowing air (between the reps
beginning and enzyming)
- Loads and weights for the structural verifications of the Buyer
- The list of spare parts
-The list of consumption materials, lubricatings, etc,
CE Certificate
All sizes will be reported to the International System; the norms in accidents prevention matter and the
Italian Technical Standard (UNI) will be respected.

TOTAL SELLING PRICE MILL_FLOOR : €.800.000,00-mill-floor

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