Oerlikon Manmade Fibers Segment From Melt to Yarn

Transcription

1 Oerlikon Manmade Fibers Segment From Melt to Yarn 2nd International Polyester Conference, Indian Polyester 2014 Atul Vaidya General Manager - Sales

2 Oerlikon Manmade Fibers Segment From Melt to Yarn

3 Oerlikon Manmade Fibers Segment Key Figures Key Figures Sales: ca. 1 bn CHF Investment in R&D: 30 Mio CHF p.a. Patents: 1160 (150 new patens p.a.) Locations/ Employees/ Production Locations: 5 production sites in 4 countries (11 sites overall) No of Employees: 2500 Productlines/ Customers Product lines: Spinning plants, texturing machines, BCF, Monofilament, Continuous Polycondensation, Staple Fiber, Nonwovens Customers: Key Account Partnership, Focus on TOP 100, ~70% sales in Asia

4 Strong Position in Volume Business with Growth Potential in Plant Engineering & Services Spinning Plants Texturing Machines BCF Carpet/Tape/Mono Plant Engineering POY, FDY, IDY spinning plants produce endless multifilament yarn for textile and technical applications DTY texturing machines crimp the pre-oriented yarn (POY) to give a cotton-like touch BCF plants produce endless multifilament yarn for home textile and carpet applications Tape & Monofilament Continuous Polycondensation (CP) Staple Fiber Plants (SF) Spunlaid, Meltblown and Airlaid solutions Customer Support: Partnering for Performance Original Parts myoerlikon.com Logistics Warehousing Installation Training Surface & Material Testing Lab R&D Center

5 Oerlikon Manmade Fibers Segment at home in growth markets and applications Apparel Other applications: Outer wear Sports wear Hosiery & socks Protective apparel Home textiles Other applications: Seat covers Upholstering Technical textiles (Filament) Technical textiles (Nonwovens) Other applications: (Seat) Belts Tarpaulin Ropes Nets Sewing threads Other applications: Agrotextiles Medical

6 Oerlikon Manmade Fibers covers two Processes of the entire Value Production Chain Petrochemicals Melt Yarn Raw fabric Treated fabric End product Application Raw material Polymer Processing (CP) Spinning Textile Processing Finishing Product Make-up Retail & Distribution PTA MEG Caprolactam Polycondensation Polymerization POY/DTY FDY IDY BCF Staple fiber Nonwoven Knitting Weaving Dying and Finishing Printing Coating/ Laminating Interior Textiles Technical Textiles Nonwovens Garments Retailer Merchant & Whole-sale Con-tractor & Supplier Carpets

7 What is an Oerlikon Melt to Yarn Concept? Full supply of value chain from RM to fiber, filament or chips MEG, PTA PET Bottle Fiber & Filament State-of-the-art plants for the production of Fiber grade: PET with or without downstream plants for the production of POY, FDY, IDY, staple fiber and nonwoven Bottle grade: PET Capacity per line up to 900 mto/d

8 Polycondensation - Key Benefits Low consumption of Raw material, Energy and Utilities Following the well know OMF philosophy of low operating expenses. For e.g: PTA chain conveyer. Vacuum ejector EG driven. Vacuume Absorbtion chiller. Key equipment by experienced vendors Basic engineering and key equipment by experienced partner As per December 2013 total of 40 poly-condensation plants are either in operation or under construction

9 Introduction What is WINGS POY? THE PROCESS process using the latest compact winding technology and spinning concepts to allow yarn producers to compete within the global market. CONCEPT Ergonomic layout Compact, floor-operated design Parallel-like yarn path Product quality-focused spinning system BENEFIT W I N G S Winding Integrated Godet Solution Energy-saving, environmentally-friendly cost-efficient process Compact and ergonomic draw field designed for excellent performance

10 Introduction WINGS PET POY success story Launched at the ITMA 2007 > 14,500 spinning positions delivered until 2013 > 8,500 spinning positions to be delivered in 2014 and 2015 Including > 3,000 WINGS 1800/12 spinning positions Status: May 2014

11 Introduction What is WINGS FDY? NEW PROCESS WINGS FDY is a new FDY process using the latest technology to allow yarn producers to compete within the global market. NEW PRINCIPLE First step: Drawing and heat treatment Second step: Finish application and interlacing OPEX cost Energy-saving and efficient process Compact and ergonomic draw field for excellent performance and lowest OPEX values Easy-to-handle process

12 Introduction WINGS FDY machines in the market > 2,000 spinning positions delivered until 2013 > 1,500 spinning positions to be delivered in 2014 and ,500 positions already sold Approx. 300 WINGS FDY pos. in operation in India Approx. 1,600 WINGS FDY pos. in operation in China Approx. 1,000 positions with 32 ends in operation Approx. 1,000 positions with 24 ends in operation Productivity total WINGS FDY product: ~ 2,300 tons/day Status: May 2014

13 The manmade fiber market OPEX determine the success of commodities Energy reduction e-save Reduced CO 2 footprint Advanced process technologies, e.g the WINGS family, EVO quench Latest, high-efficient components used Labor costs Optimized workflows Easy m/c operation Easy-access m/c Compact plant layout High production density with 24e/32-end zigzag spin beams No operator platforms Standardized m/c concept Easiest commissioning and start-up Reliability 100% tested Fully assembled modules Long-term/long-life design specification Waste prevention Fastest start-up Robust and stable process technology

14 2-Step Staple Fiber Plant - Characteristics and Advantages Main Characteristics Spinning speed: 600-2,500 m/min Drawing speed: m/min Capacity: up to 300 tons/day Titer range: dtex Advantages Highest fiber quality Fine titer staple fibers Highest Capacity Page 14

15 Key Benefits Full supply of value chain Low OPEX Full supply of value chain Approved quality Worldwide Service Network Experienced Execution Single source technological package Polycondensation plant including all utilities e.g. tank farm, PTA unloading etc. Melt transfer line to Spinning facilities. Filament, fiber or nonwoven plants Single source financial package One highly skilled sales team No financial risks created by unconsidered technological components or interfaces Option for one single LC resulting in: Potential for Hermes covered ECA loan agreement Single source construction package Coordinated execution to ensure start-up date and start of production Full coordination by experienced people of Oerlikon

16 Key Benefits Approved quality Low OPEX Full supply of value chain Approved quality Worldwide Service Network Experienced Execution Detail engineering by Oerlikon Barmag Experienced engineering groups in Remscheid and India Technical personnel for all disciplines like process, mechanical, instrumentation, piping, etc. Successful execution of two integrated polycondensation and POY/FDY plants in India, with totaly four lines Successful execution of one integrated CP & SSP plant in India and one in Egypt High process and component quality Optimum spinning results.

17 Key Benefit Worldwide service network Low OPEX Full supply of value chain Approved quality Worldwide Service Network Experienced Execution Technical Service World wide service network 24-h emergency support Service stations close to you Professional services, on-site and remote USA Charlotte, NC Germany Remscheid Neumunster Chemnitz Turkey India Mumbai Vadodara China Beijing Shanghai Suzhou Wuxi Taiwan Hong Kong 24/7 service hotline Indonesia Speaking your language

18 Key Benefits Experienced Execution Low OPEX Full supply of value chain Approved quality Worldwide Service Network Experienced Execution Reliable and stable business partner Top references

19 Key Benefits Experienced Execution Low OPEX Full supply of value chain Approved quality Worldwide Service network Experienced Execution Fiber Grade, 2008 (India) (1/2) including polymer transfer line including POY WINGS 10 ends including FDY I-QOON 24 ends EP contract with supervision of construction 1 line à 300 mto/d, semi dull commissioning in 2008 Bottle Grade, 2012 (India) EPC contract 1 line à 600 mto/d 1 line à 700 mto/d SSP including utilities

20 Key Benefits Experienced Execution Low OPEX Full supply of value chain Approved quality Worldwide Service network Experienced Execution Fiber Grade, 2014 (India) (2/2) including polymer transfer line including POY WINGS 20 ends including FDY WINGS 24 ends including FDY WINGS 32 ends EP contract with supervision of construction 3 lines à 200 mto/d for different lusters PET Commissioning of line 1&2 in 2013, line 3 in 2014 Bottle Grade, 2013/2014 (Egypt) EPC contract 2 lines à 600 mto/d 2 lines à 700 mto/d SSP Commissioning of line 1 in 2013, line 2 in 2014 including utilities

21 Thank you.