Oerlikon Polymer Processing Solutions Division’s sustainability program, e-save, has saved over 15 million tons of CO2 in 20 years, according to its financial sheet. Since 2004, the company, which is among the top providers of artificial fiber plant technologies globally, has been creating, manufacturing, and introducing its goods and services with sustainability as a top priority. The four e-save topics—”energy savings,” “efficiency” of systems, machines, and components, “environment relief,” and improved “ergonomics” for optimal machine operation—have given fiber and yarn manufacturers a tremendous boost in terms of economy, safety, and process handling from the beginning. In terms of sustainability, the founders of the brands Oerlikon Barmag, Oerlikon Neumag, and Oerlikon Nonwoven were already true pioneers.
The e-save objective of Oerlikon is validated by factors such as escalating energy costs, limited resources, aging populations, insufficient skilled labor, and reduced profit margins across several sectors. The industry leader in artificial fiber production technology has been winning awards for the past 20 years by using a lot less energy than its competitors, the market norm, or even its own previous models. Global producers of fiber and yarn are grateful for this, since new systems created with e-save standards pay for themselves considerably more quickly. According to Georg Stausberg, CEO of the Oerlikon Polymer Processing Solutions Division, “topics like energy efficiency and the careful use of resources have become increasingly important for all our customers in recent years, not least due to stricter legal framework conditions.””We frequently have the decisive advantage in numerical investment decisions on the customer side and thus the edge over the competition thanks to our e-save sustainability program and the associated technology development over the last two decades.”
More than 15 million tons of CO2 have been saved since e-save was implemented.
For several decades, the Oerlikon Polymer Processing Solutions Division and its business units have been certified by DIN ISO. They have also obtained the CE marking and continuously adhere to stringent guidelines for machine safety, particularly with regard to safeguarding customer staff. But this was insufficient at the start of the new millennium. With an eye on the future, the company and its managers wished to willingly undertake even more. Consequently, the e-save initiative was introduced in 2004.
Since its launch, Oerlikon Barmag, Oerlikon Neumag, and Oerlikon Nonwoven technology solutions have been installed in hundreds of spinning mills for man-made fibers throughout the world. Oer-likon technology underpin around half of the presently installed production capacity for nylon, polyester, and polypropylene. This amounts to around 40 million tons of fibers and yarn yearly, according to an estimate made by the publication “TheFiberYear 2024.” Impressive is the equivalent CO2 balance: almost the course of the last 20 years, the installations of e-save certified customers have prevented almost 15 million tons of CO2 emissions. This is roughly similar to the amount of carbon stored in a forest the size of Munich, Germany, with a surface area of 300 km², or the emissions produced by almost 15 million international passenger trips per capita.
Energy savings are possible when heating and cooling systems are efficient.
What were the engineers first concentrating on? A key component of polymer spinning systems is heat. Between 280 and 290 degrees Celsius, polyester melt is transported from the polycondensation facility to the spinning system. Depending on the procedure, the hot filament emerging from the spinnerets is then cooled in the quenching unit before being dragged on hot godets.
“All of this might lead to an optimal use of energy: At ITMA 2007, WINGS POY (Winding Integrated Godet Solution) completely changed the man-made fiber market. The entirely new winding concept has already demonstrated the ability to radically upend the sector.The Oerlikon Polymer Processing Solutions Division’s CTO, Jochen Adler, notes that “all market participants were enthusiastic from day one.” Particularly Chinese businesses were already aware of the technology that would position them as world leaders in the synthetic fiber sector. Five years later, with even greater e-save benefits, particularly in the area of energy savings, WINGS FDY took the market by storm. When compared to the industry norm at the time, the Oerlikon Barmag invention achieved an energy consumption reduction of almost 40%. The ROI (return on investment) was and is still attained quite rapidly. Thus, economically speaking, the best technology of the highest caliber is also valuable. Oerlikon Bar-mag core technology is complemented by WINGS -an essential component of a contemporary man-made fiber spinning machine; the business has established benchmarks with other energy-saving parts throughout the years.
Industry benchmarking market
For instance, the SP8x spinning head series has significantly enhanced insulation and a smaller heat-radiating surface than its preceding models, which results in a reduction of almost 40% in heat loss. In actual terms, this translates to an annual energy savings of almost 200,000 kWh for a system with 36 roles. As a result, the component continues to be the industry standard.
“The EvoQuench radial quenching system’s up to 80% lower air conditioning requirement makes it a true money maker. Depending on the process, up to 46% energy and almost 50% trash can be saved when using the WINGS take-up system in comparison to conventional technology, according to Adler. The latter is mostly attributable to the take-up unit’s novel ergonomic concept: In record time, the component is positioned at eye level; just one operator is needed.
At an exceptionally early stage, the sibling business Oerlikon Neumag also donated corresponding e-save components. For instance, the BCF tangling unit RoTac3’s tailored use of compressed air results in significant energy savings. Unlike continuous airflow, which is the case with typical tangle operations, pulsing airflow is used to form tangle knots. Thus, pressurized air is only ever needed in order to construct a tangle knot. Depending on the type of yarn, this can cut the necessary volume flow or compressed air consumption by as much as 50% as compared to traditional tangling units. The part is naturally installed in the most advanced carpet yarn system in the world, Oerlikon Neumag’s BCF S8 system.It has a major impact on the energy-efficient carpet yarn production process. But the system’s basic concept—a 99% plant efficiency, 15% greater throughputs, and up to 5% energy savings per kilogram of yarn—also makes an excellent case with facts.
Increased productivity with less energy
The Oerlikon Barmag eAFK Evo provides 30% more productivity with 20% reduced energy usage per kilogram of textured yarn as compared to traditional DTY machines. In comparison to a typical machine, the machine’s speed has increased significantly, and its 50% shorter texturing zone ensures an exceptionally reliable texturing process that maximizes production while minimizing operational expenses. The EvoCooler, the machine’s central component, operates on the sustainable cooling principle of water evaporation. With direct contact to the yarn, this active cooling technique operates independently of the surrounding temperature and doesn’t require any extra energy. Furthermore, less heat radiation into the surrounding air means less hall air conditioning is needed. Since the collected coolant is circulated, it is recyclable.
The textile value chain’s precisely timed process steps have the potential to be more efficient. One such is the eAFK Big V high-titer idea and WINGS POY HD, which are intended for a carpet and home textile product line that combines especially thick and soft polyester yarns with BCF-like qualities. Producing yarns with a maximum count of 1200den and more than 1000 filaments is the goal here. A DTY machine is used to spin together DTY yarns up to 1200den with up to 1152 filaments from four POY bob-bins 300den/288f, according to Jochen Adler. A basic drawback of the procedure is that half of a texturing machine’s possible winding places go unused. This is where the spinning concept—currently the only one on the market—offers a highly effective solution: a combination of an automatic eAFK Big V multi-spindle texturing machine and a WINGS POY HD take-up unit.
Water: a resource that is disputed
The Oerlikon Neumag EvoSteam staple fiber mill is the most recent illustration of a sustainable e-save technology. Additionally, throughout development, the pertinent sustainability-related process stages were already taken into consideration. There is no need for water baths in this novel procedure. As a result, up to 3.5 million liters of water can be saved annually, drying energy and preparation consumption are greatly reduced, and the CO2 footprint can be reduced by up to 20%. The EvoSteam staple fiber technology is up to 12% more efficient than earlier ideas thanks to an enhanced draw point release. All things considered, the EvoSteam method can save up to 8% energy and reduce manufacturing waste by up to 50%.
Another illustration: the issue of textile dyeing contaminating water is one that is frequently discussed. Manmade fiber production provides an extraordinarily clean alternative by allowing color pigments to be injected as a masterbatch as early as the melt preparation step, thanks to the 3DD mixer technology that was formerly created at Oerlikon Barmag. A pleasant bonus is that the color fastness of these spun-dyed yarns is unmatched, and the dyeing is far more uniform than that of bath-dyed bobbins or textile surfaces. Furthermore, the spun material virtually never loses its color.
Finally, but just as importantly, the textile sector as a whole is working to find answers for a sustainable, comprehensive circular economy. Oerlikon Bar-mag already offers at least one solution for a zero waste manufactured fiber spinning machine, in collaboration with its joint venture partner BB Engineering. Production waste can be high-quality reprocessed in the spinning mill with the aid of VacuFil technology, allowing the waste material to be returned into the melt flow.
Top: accreditation from Bluesign®
About two decades after Oerlikon first introduced the e-save label as a voluntary commitment, the company is now following suit and submitting to evaluation by independent organizations like the Swiss bluesign Technologies AG as part of the ESG requirements that are now legally required.
The Oerlikon Neumag EvoSteam staple fiber facility received the bluesign® VERIFIED DATA certification last year. A plausibility assessment of the supporting documentation for the EvoSteam draw frame, the focal point of the EvoSteam process, was used to verify impact statistics, including water, spinning preparations, thermal and electrical energy, and the CO2 footprint.This implies that all polyester staple fibers made using the EvoSteam process will actively participate in the bluesign® SYSTEM going forward, which is good news for yarn manufacturers.
More sustainability is becoming more than simply a trend; it is essential for the global market and industry players alike. In addition to our own e-save label, we are giving our clients even more transparency in anticipation of the European Green Deal by obtaining external certifications like bluesign®. As Chief Sustainability Officer (CSO) of the Swiss Oerlikon Group in addition to serving as Division CEO, Georg Stausberg says, “In this way, we are intensively strengthening trust in all our products and services.”
First caption:
Machines and parts from Oerlikon Barmag, Oerlikon Neumag, and Oerlikon Nonwoven that are substantially more environmentally friendly than the industry norm or earlier models are given the e-save logo.
Caption 2+3: The e-save sustainability program’s CO2 balance is remarkable. almost the course of the last 20 years, the installations of e-save certified customers have prevented almost 15 million tons of CO2 emissions. This is about similar to the amount of emissions stored in a forest the size of Munich, Germany, with a surface area of 300 km², or the emissions produced by almost 15 million intercontinental passenger flights per individual.
Caption 4: Oerlikon has established multiple large-scale plants across the globe in the last 20 years to produce several hundred tons of nylon, polyester, or polypropylene each day.
Caption 5: At the ITMA 2007, Oerlikon Barmag’s WINGS POY (Winding Integrated Godet Solution) transformed the man-made fiber sector. The popular winder now comes in a whole product line.
Caption 6: Oerlikon Barmag has established itself as one of the leading providers of artificial fiber systems for both POY and FDY thanks to WINGS (Winding Integrated Godet Solution).
Caption 7: With an air conditioning requirement up to 80% lower than other systems, the EvoQuench radial quenching system is a genuine money maker.
Caption 8: Among other things, the Oerlikon Barmag eAFK Evo’s revolutionary EvoCooler allows it to achieve 30% higher output with 20% less energy usage per kilogram of textured yarn than ordinary DTY machines.
Caption 9: Oerlikon Neumag BCF S8 also dazzles with remarkable facts because of the general idea: up to 15% greater throughputs, up to 5% system efficiency, and up to 5% energy savings per kilogram of yarn.
Caption 10: The Oerlikon Neumag BCF RoTac³ tangling unit uses compressed air in a tailored manner to provide significant energy savings.
Caption 11: The Oerlikon Neumag EvoSteam staple fiber system is the most modern illustration of sustainable e-save technology. The pertinent sustainable process stages were also taken into consideration throughout development.
Caption 12: The bluesign® VERIFIED DATA designation was given to the Oerlikon Neumag EvoSteam staple fiber technology the previous year.
Caption 13: Georg Stausberg is the CSO of the Swiss Oerlikon Group and the CEO of the Oerlikon Polymer Processing Solutions Division.
Caption 14:Jochen Adler is the Chief Technology Officer of the Oerlikon Polymer Processing Solutions Division.
