Truetzschler OPTIMA for 4-end BCF spinning
The Truetzschler OPTIMA concept which was designed as a single machine for carpet filament yarn production initially has now evolved into a system platform, with the introduction of the MO40-E. Truetzschler Man-Made Fibers’ Optima range of carpet yarn machines consists of the compact MO40-C extrusion system for standard yarn and the MO40-E for standard and specialty Bulk Continuous Filament (BCF) yarn production.
MO40-C – a 4-end extrusion system for standard BCF filament yarns
Unveiled at ITMA 2019, Barcelona, the Truetzschler “OPTIMA” is a proprietary 4-end carpet yarn machine. Today, MO40-C BCF systems are running stably and efficiently at various customer sites.
Figure 1 Truetzschler MO40-C
The production window of the MO40-C is impressive as 4 ends can be spun and wound simultaneously on bobbins. The high productivity of 4 yarn ends applies to the MO40-C not only for standard yarns but also for finer low-dpf (denier per filament) qualities down to 1.5 dpf. Thanks to a very short melt line from the extruder to the spin beam and the symmetrical yarn path through the machine, four high-quality, identical threads are created. Each bobbin of a spinning position has the same yarn characteristics in each section. The minimum yarn count for 4 bobbins is 500 dtex, by plying two threads and 2 bobbins, with up to 6,000 dtex being produced in one position.
A main objective of the OPTIMA project was to reduce the space required for one spinning position. With a footprint of 2,000 mm x 2,000 mm, the MO40-C can fit in a small space if the system has to be planned into an existing hall. Even in a new building, the MO40-C’s high production output per square meter is a notable feature. In fact, the MO40-C has the industry’s highest throughput of yarn per square metre of production space.
Figure 2 Truetzschler MO40-EMO40-E - a flexible solution for high count and standard yarn qualities
In recent years, the demand for smooth, velvety carpet surfaces has increased. Innovations in this area are in demand because only a large number of finest carpet yarns can produce the desired velvety-smooth surface effect. The production of so-called high-count yarns with the smallest single filament titre is demanding – but with the new MO40-E it is within reach.
More filaments in a BCF yarn require more and larger spinnerets. This leads to larger spin packs and wider spin beams. High-quality yarns are only created if the still hot and soft individual filaments do not stick together after the spinnerets are all evenly cooled. The MO40-E therefore also has a widened quenching cabinet so that the cool process air reaches all the individual filaments evenly.
Figure 2 Truetzschler MO40-E
The Truetzschler OPTIMA concept which was designed as a single machine for carpet filament yarn production initially has now evolved into a system platform, with the introduction of the MO40-E. Truetzschler Man-Made Fibers’ Optima range of carpet yarn machines consists of the compact MO40-C extrusion system for standard yarn and the MO40-E for standard and specialty Bulk Continuous Filament (BCF) yarn production.
MO40-C – a 4-end extrusion system for standard BCF filament yarns
Unveiled at ITMA 2019, Barcelona, the Truetzschler “OPTIMA” is a proprietary 4-end carpet yarn machine. Today, MO40-C BCF systems are running stably and efficiently at various customer sites.
Figure 1 Truetzschler MO40-C
The production window of the MO40-C is impressive as 4 ends can be spun and wound simultaneously on bobbins. The high productivity of 4 yarn ends applies to the MO40-C not only for standard yarns but also for finer low-dpf (denier per filament) qualities down to 1.5 dpf. Thanks to a very short melt line from the extruder to the spin beam and the symmetrical yarn path through the machine, four high-quality, identical threads are created. Each bobbin of a spinning position has the same yarn characteristics in each section. The minimum yarn count for 4 bobbins is 500 dtex, by plying two threads and 2 bobbins, with up to 6,000 dtex being produced in one position.
A main objective of the OPTIMA project was to reduce the space required for one spinning position. With a footprint of 2,000 mm x 2,000 mm, the MO40-C can fit in a small space if the system has to be planned into an existing hall. Even in a new building, the MO40-C’s high production output per square meter is a notable feature. In fact, the MO40-C has the industry’s highest throughput of yarn per square metre of production space.
Figure 2 Truetzschler MO40-EMO40-E - a flexible solution for high count and standard yarn qualities
In recent years, the demand for smooth, velvety carpet surfaces has increased. Innovations in this area are in demand because only a large number of finest carpet yarns can produce the desired velvety-smooth surface effect. The production of so-called high-count yarns with the smallest single filament titre is demanding – but with the new MO40-E it is within reach.
More filaments in a BCF yarn require more and larger spinnerets. This leads to larger spin packs and wider spin beams. High-quality yarns are only created if the still hot and soft individual filaments do not stick together after the spinnerets are all evenly cooled. The MO40-E therefore also has a widened quenching cabinet so that the cool process air reaches all the individual filaments evenly.
Figure 2 Truetzschler MO40-E
MO40-C and MO40-E in comparison:
| MO40-C (Compact) | MO40-E (Extended) | |
|---|---|---|
| Position pitch (mm) | 2000 | 2500 |
| Max. no. of filaments | 500 | 750 |
| Titre range (dTex)1 | 500 - 60002 |
7503 - 70002 |
| dpf range (dTex)5 | 1.5 - 28 | 1.5 - 28 |
| Spinneret width (mm) | 240 | 400 |
| Quench cabinet width (mm) | 1255 | 1760 |
Note: Depending on polymer and number of filaments:
1 2 different spin packs
2 Assembled/plied
3 MO40-E spin pack
4 Standard MO40-C spin pack with adapter
5 Depending on polymer, number of filaments and texturing
Since high-count yarns are a niche product, the MO40-E is also designed to produce standard BCF with titres of 3 dpf or more. The working window ranges from 500 to 7,000 dTex. In these cases, a standard spin pack is inserted into the spin beam with the help of an adapter.
Figure 3 The MO40-E can produce standard or high-count yarn The increased flexibility has its price: the larger spin packs for the high-count yarns require a wider spin beam and a higher pitch of 2,500 mm. The residence time of the melt remains very short despite the structural adjustments.
Figure 3 The MO40-E can produce standard or high-count yarn
A.T.E. has more than 80 years of experience in the Indian textile industry and provides end-to-end solutions across the textile value chain. Its domain knowledge and relationships have made it a sought after partner for carpet manufacturing machinery.
