Allma and Volkmann Twisting and Cabling Systems competence in twisting
competence in twisting Allma Product Line Volkmann Product Line
Oerlikon Saurer is a Business Unit in the textile segment of the globally successful technology group OC Oerlikon. With groundbreaking technological innovations, Oerlikon Saurer and their product lines Allma and Volkmann are the leading international suppliers of top-performing twisting and cabling systems. Product innovations which are tailor-made to customers needs together with an extensive range of services guarantee a high degree of production reliability as well as maximum added value and value retention. The extremely motivated and competent team of the Allma and Volkmann Product Lines ensures the long-term continuity of these values. Being a market leader is a commitment For decades already, the Allma Product Line has been constantly setting new technological milestones in twisting technology. Allma production systems offer leading technology all over the world for tire cord and technical yarns. For more than 100 years already, the name of Volkmann has stood for high-quality twisting machines. The global success in the market segments staple fibre yarns, glass filament yarns and carpet yarns is based upon years of close cooperation with our customers. The following applies to both the product lines: Our staff create innovations which serve to improve quality and productivity and which are geared completely to the needs of our customers, and to the requirements of the markets and further processing. Comprehensive service reliability Oerlikon Saurer customers benefit not only from an excellent product quality but also from a variety of services rigorously adapted to their individual profiles. The spectrum ranges from operation planning with comprehensive advising, erection, commissioning, training, laboratory tests plus inspections and maintenance right through to reliable product supervision and procurement of original spare parts even decades after purchase. The application technology centres and customer training facilities are spacious and equipped with a state-of-the-art infrastructure. Twisting and cabling systems at a glance Market Process Machine type Technical yarns Hybrid yarns Two-for-one twisting Allma TC2 Tire cord Direct cabling Allma CC4 Direct cabling Two-for-one twisting Allma CC3 Staple fibre yarns Two-for-one twisting Volkmann CT Volkmann FT Carpet yarns Two-for-one twisting Direct cabling Heatsetting Volkmann CC Volkmann HS Glass filament yarns Ring twisting systems Volkmann GT Oerlikon Saurer Product Overview 3
Competence in Twisting Technical Yarns From the sturdy rope for eternity via media-effective races with high tech sport sailing culminating in the finest yarn in vital human organs this is the world of technical yarns. High-quality products for industries with innovative and top-performing applications: in mechanical engineering, in medical technology, in aviation and space travel, in the future-oriented energy-optimised automobile industry, in the building industry and many other applications in countless products for today and tomorrow. There is an unbelievable variety of opportunities for technical yarns. Allma products for successful companies Trying something new, making tomorrow s world even better and even more worth living, and working in close collaboration with customers to make these ideas become reality these are the incitements and keynotes responsible for the success and reputation of Allma products. Allma customers benefit from technological leadership and top quality machine construction together with a long-standing partnership of mutual trust. Opening up new markets In order to meet the requirements of tomorrow, Allma Product Line develops market-oriented and custom-tailored solutions. Allma twisting and cabling systems focus on quality, flexibility and economic efficiency when giving our customers the competitive edge with innovative developments. Our emphasis is clearly on the market requirements of the future. This makes the Allma TC2 a success guarantee for each production, because it surpasses the status quo in every respect and sets new standards. 4 Oerlikon Saurer Product Overview
Allma TC2 Two-for-one twisting machine for all technical yarns made of single and multiple yarns For opening up new markets. Spindle sizes of 280 to 330 for your individual production requirements Delivery speed up to 450 m/min Machine up to 120 spindles Your advantages Unique material flexibility, e.g. PA, PES, PP, PE, CV, AR, PVA, Dyneema, etc. Large count range from 235 dtex to 60,000 dtex Maximum production flexibility thanks to individually controllable spindles Range of twists from 12 to 733 tpm Unbeatable productivity thanks to delivery speed of up to 450 m/min Allma PrimePac Top package quality with up to 25 percent higher package density Electronically controlled thread reserve PreciTail Pneumatic threading system AiroMat Doubling device for multi-ply constructions and hybrid yarns with up to 6 single yarns Highest twist and package quality due to online monitoring and controlling of the entire process Easy operation through worldwide unique machine concept Oerlikon Saurer Product Overview 5
Competence in Twisting Tire Cord Enormous demands are made on tires and thus on tire cord: complete safety, maximum loading capacity and the greatest comfort possible. Fulfilling these demands satisfactorily is the secret of successful tire manufacturers. The willingness to develop innovative products is particularly pronounced in this prestigious segment. Run-flat tires or inventive rubber compounds which lower energy consumption even further, are examples which really guarantee success. Allma winning performance The tire industry relies on new technologies in order to be equipped for the market demands of the future. Allma Product Line works together with customers in the development and implementation of product innovations and supports them with technical solutions and know-how. Allma tire cord machines represent a market share of approx. 65 % of the world s tire cord production. Allma Product Line is thus the world s largest twisting and cabling machine manufacturer for the tire industry. All tire manufacturers benefit from the uncompromising production quality, reliability and costeffectiveness of our range of products and services. Convincing answers Allma Product Line has optimal machine solutions for the most varied production requirements. All raw materials can be produced with the desired quality and cost-effectiveness on Allma machines. Whether for the mass market or the high-end segment, with the Allma cabling and twisting systems customers can choose the solution they need. A technical feature which sets us apart is for example the newly developed outer yarn delivery system, which allows energy savings of up to 50 %, thus setting a new milestone in the cabling technology. The constant quality monitoring of each individual spindle ensures a consistently high cord quality. 6 Oerlikon Saurer Product Overview
Allma CC4 the energy-saving miracle Award-winning direct cabling machine for the manufacture of high-quality balanced 2-ply tire cord. Spindle sizes of 205 to 290 for economical use to meet your individual requirements Spindle speed up to 11 000 rpm Machine up to 168 spindles Yarn count range from 940 to 2520 dtex Your advantages Energy consumption reduced by up to 50 % compared with other models in the market Heat load reduced by up to 50 % Up to 50 % fewer yarn breaks Significantly reduced noise level Maximum economic efficiency and quality Allma CC3 High-performance cabling and twisting machine with ultimate flexibility for the manufacture of high-quality 1- to 3-ply tire cord and technical yarns. Two-for-one package for twisting cap ply, chafer and further technical yarns up to a maximum of 120 m/min delivery speed. Also for twisting of unbalanced 2-ply and balanced and unbalanced 3-ply tire cord Your advantages Maximum flexibility thanks to cabling and two-for-one twisting on the same machine Processes all materials in the tire cord industry High-grade components in the yarn path ensure the processing of even the most sensitive materials such as rayon and aramid Same lengths on twist packages Reduced staff requirement Oerlikon Saurer Product Overview 7
Competence in Twisting Staple Fibre Yarns In the wide-ranging market for staple fibre yarns, fashion trends such as, for instance, finer and finer yarn counts and the quality demands made on the yarns used, are still the decisive factors for success. The need to reduce energy costs and increase profitability are basic parameters which are of decisive importance in today s globalised competition. For us, this means targeting our development and designing technologies with the help of which twisting mills can manufacture high quality products, lower their energy costs and thus further optimise their profitability. Volkmann e-save high tech for staple fibre yarns Besides research and development, Volkmann has for many years been giving top priority to intensive product management and market support, and the knowledge gained has been used for furthering product development. Volkmann production systems are based on the synthesis of tried and tested techniques and the most progressive technology. Energy-optimised drives plus further components and elements based on reducing energy costs make Volkmann twisting machines pioneers of new technologies, for instance with the new eco spindles and eco drive technology with their enormous savings potential of up to 40 %. In this way, our customers are assured of many years of competitiveness even when market conditions become tougher. Every Volkmann production system is designed today already for the markets of tomorrow and is geared to the specific market requirements and wishes of the customers. For all staple fibre yarns from the mass product to the most exclusive designer wear every customer has their individual solutions based on the Volkmann CT (CompactTwister) and the Volkmann FT (FusionTwister). 8 Oerlikon Saurer Product Overview
Volkmann CT High-performance twisting machine with a large variety of functional options for all staple fibre yarns. e-save: - eco spindles - eco drive technology Delivery speeds of up to 120 m/min on 6 - and 8 -crosswound twist packages Electronic headstock with servo drive technology 6 up to 2 x 6 direct feed «TwinPack» for conical formats 4 20 and 5 57 Your advantages Process step doubling is eliminated with polyacrylic and knitting yarns Optimal adaptation of the crosswound twist packages to the subsequent processes Shortest machine changeover times Excellent yarn results Volkmann FT Performance-optimised twisting machine for yarns in the medium and fine yarn count range. e-save: - eco spindles - eco drive technology High productivity with spindle speeds of up to 15 000 rpm Mechanical headstock for delivery speeds of up to 80 m/min Up to 240 spindles in four spindle sizes with and without antiballoon ring Best quality of crosswound twist packages Your advantages Excellent price-performance ratio Highly reliable Easy operation Low maintenance requirement Oerlikon Saurer Product Overview 9
Competence in Twisting Carpet Yarns One of the main characteristics of the carpet market is its fashion diversity. The design possibilities are endless and always dynamic, and creativity is indispensable to keep up with competition. Looks, comfort, structure and costs are the parameters which decide a carpet s success. As a supplier of cabling and twisting machines for carpet yarns, Volkmann Product Line is very well aware of these challenges and can offer solutions which help the carpet yarn manufacturer to be part of this varied, lively market and to be able to competently fulfil even the most demanding requirements. In Volkmann Product Line, our customers have a reliable, long-standing partner who sets standards with regard to solid machine construction and textile processing technology. With Heat-SET, i.e. by integrating heatsetting in the cabling process, Volkmann Product Line sets a new milestone in the manufacture of carpet yarns. Volkmann carpet yarn solutions combining experience and vision A secret of good carpet yarns is a combination of traditional values with state-of-the-art technological developments and findings. For decades already, Volkmann products have been at the forefront of carpet development with their innovative and reliable two-for-one twisting and cabling machines. In close collaboration with many renowned carpet manufacturers, Volkmann products are in constant and successful development. Integrating Heat-SET realising visions Heat-SET allows for cabling and heatsetting the carpet yarn in one process run. This considerably shortens the process chain and new standards with regard to economic efficiency, flexibility and process management are set. 10 Oerlikon Saurer Product Overview
Volkmann CC Two-for-one twisting and cabling machine for the production of carpet yarns. Perfect carpet yarns Extremely cost-effective Processing of all standard yarn qualities State-of-the-art machine handling Ergonomic creel, optionally with pneumatic support Creel yarn tensioners for special yarns Pneumatic threading Quality monitoring Individual adjustment to customer requirements Volkmann HS Setting new standards with regard to economic efficiency, flexibility and process management. Heat-SET process Cabling, heatsetting and winding all in one process run Decisive competitive advantages Reduced handling Less material in process Less waste Reduced space requirement Simplified workflow management Shorter processing times Oerlikon Saurer Product Overview 11
Competence in Twisting Glass Filament Yarns A market with a promising future for products which do not yet exist; constantly growing and full of innovations. This is how the market for twisted glass filament yarns could be described. Mainly for printed circuits, but also in special applications. Minimal electrical conductibility and resistivity make textile glass ideal for use in the electronics industry. Advanced production systems are a basic prerequisite for the manufacture of twisted glass filament yarns for this highly dynamic market. Volkmann sets new standards Besides the hitherto existing customer requirements such as reliability, yarn quality and cost-effectiveness, new parameters are gaining in importance in glass filament production: a high technological standard, performance and ergonomic innovations are making a large contribution to its success. The Volkmann Product Line achieved a major breakthrough with the further development of the Volkmann GT (GlassTwister). This innovative high-performance ring twisting machine has really proven itself in the market and has set new standards with its technological features. Among these are state-of-the-art drive components for the creel baskets, ring rail and ring twisting spindles, central setting via touchscreen plus the constant monitoring of the process parameters and production data together with a host of further elements. The result is first-class glass filament and bobbin qualities. 12 Oerlikon Saurer Product Overview
Volkmann GT Innovative high-performance ring twisting machine for up twisting glass filament yarns. Slip-free drive components: Creel baskets with separate drive Precise separate motor drive for the ring twisting spindles Servo drives for controlling the ring rail movement Data input and data query: central setting of all product parameters on touchscreen Monitoring of process parameters and production data Drying systems Various drying systems are available as an option for the Volkmann GT. Customers have a choice of three designs, namely using air, steam or infrarot drying. In addition, they can order the machines as an enclosed model. We shall be happy to answer all our customers questions on suitable drying systems, in collaboration with proven specialists. Your advantages Maximum reliability Best yarn and finished bobbin quality Excellent cost-effectiveness Great flexibility Low energy consumption Low noise level State-of-the-art machine handling Ergonomic and user-friendly machine Individual adaptation to customer requirements Oerlikon Saurer Product Overview 13
Why e-save? Save energy costs with e-save All the signs are clear: energy will become more and more scarce and more and more expensive. So energy savings in production are of major importance. There is an ever greater willingness to invest in new technologies in order to achieve energy-efficient production that is in line with the market. The products from Allma and Volkmann Product Lines offer innovative solutions together with increased energy efficiency. Allma and Volkmann machines which have reduced their energy consumption by at least 20 % compared to the market standard receive the e-save certification. These machines from Oerlikon Saurer, Allma Product Line, are e-save certified Allma TC2 Allma CC3 Allma CC4 14 Oerlikon Saurer Product Overview
Conventional power e-save rpm Allma CC4 Allma CC3 Volkmann CC Volkmann CT/FT Allma CC4 is a new milestone in the successful energy efficiency programme e-save at Oerlikon Saurer. The new future-oriented technology enables energy savings of up to 50 %. Besides optimised spindle geometry, the new e-save spindle technology for Volkmann CC (CarpetCabler and Carpet- Twister) and Allma CC3 (CableCorder) offer the customer decisive advantages with regard to flexibility, twisting and cabling as well as a wide yarn count range. The new eco spindle technology and the eco drive concept for Volkmann CT (CompactTwister) and Volkmann FT (FusionTwister) impress with an energy savings potential of up to 40 %. These machines from Oerlikon Saurer, Volkmann Product Line, are e-save certified Volkmann CC Volkmann CT Volkmann FT Oerlikon Saurer Product Overview 15
Customer Support Security for investments, added value and product quality As a perfect complement to their plants and components, Oerlikon Saurer offer their customers one of the most comprehensive ranges of services. Plant planning which is tailor-made to the customer s individual requirements, thorough instruction and training, supplying of original spare parts even decades after installation of the plant the services which Oerlikon Saurer offer are a guarantee of productivity and value retention. Instruction and training Training is a tradition at Oerlikon Saurer. We use our experience and know-how to train the users and fulfil the learning objectives developed together with the customer, using both practical and theoretical methods. To ensure this, professional instructors at Oerlikon Saurer work in large training centres equipped with the latest textile technology. We also train the operating staff on site in the customer s factory if so desired. Training information and dates can be found on our homepage and in the customer portal myoerlikon. Counselling and technological support Experienced inspectors are constantly on the road to assist their customers. In addition, fully equipped service depots and competent service teams are at your disposal on the spot in all the major textile markets. Whether erection, commissioning or inspection well-founded advice and optimal care are guaranteed. Oerlikon Saurer is available with advice to customers on all aspects of twisting. Our specialists in the technology centres assemble individual process data, carry out testing, evaluate the results and ensure that optimal yarn qualities are obtained. Maintenance and repairs Oerlikon Saurer guarantees worldwide servicing and maintenance services for its product lines Allma and Volkmann as well as health-checks for customers plants. When problems and questions arise, qualified personnel in fully equipped Repair Centres offer efficient, fast solutions thus ensuring minimum downtimes of your plant. This is backed up by efficient logistics and a stock management geared to your needs. 16 Oerlikon Saurer Product Overview
Upgrades for machines The plants of the Allma and Volkmann Product Lines stand for reliability and quality. After years of constant deployment, it makes sense to adapt these machines to the latest technological standard in order to increase their productivity and reliability. In order to let older plants benefit from the results of our research and development, Oerlikon Saurer regularly offers customers interesting upgrade packages. Integrating elements of state-of-the-art techniques and technologies into existing machines maintains the value of an investment also in the long term. Original spare parts service Machines must produce in order to be lucrative. In order to keep machine downtimes to an absolute minimum, the original spare parts ordering system SECOS is available to customers day-in and day-out. Machine and customer-specific original spare parts are available online right around the clock via an uncomplicated, safe system. Efficient global logistics together with customer-orientated stock management ensure optimal availability and guaranteed production. Oerlikon Saurer Product Overview 17
myoerlikon access to success myoerlikon.com is the future-orientated online portal for Oerlikon Saurer customers. myoerlikon.com gives reliable answers fast and clearly to all questions regarding products and production. Its innovative modules give you full support: SECOS for purchasing, merchandise planning and stock management, and in production you can rely on the online documentation for servicing, maintenance and troubleshooting. SECOS 24/7/365 The successful e-commerce tool from Oerlikon Saurer - SECOS has been tried and tested many times over. More and more customers all over the world are turning to this online ordering system to purchase their original spare parts. Closely linked to our ERP system and the global logistics management, SECOS offers optimal availability and ultra-fast delivery, making additional savings on cost-intensive warehousing. Thanks to its intuitive user interface, SECOS is very easy to use. Online documentation With the online documentation, users of myoerlikon.com have access at all times to the latest documents of their individual machine park. Here, too, the particularly user-friendly interface and a search function provide the required information fast and accurately. Trouble-shooting The trouble-shooting handbook provides practical aid for self-help. At the touch of a button, the knowledge and experience of our engineers and technicians is available to you online. With the targeted error search, you can minimise machine breakdowns. Regular updates guarantee constant availability of the latest knowledge and information. Knowledge database The knowledge that has been assembled and made available here helps our customers to achieve optimal process sequences and product qualities, and at the same time enables them to train their own personnel. You benefit from the latest knowledge of techniques and technologies, machines and material. News Here you can find everything you need to know. One glance saves time-consuming research and points the way to solutions such as upgrade packages, modernisation, special offers, practical experience reports, background analyses, tips, addresses and much more. Test myoerlikon Visit us now and see how myoerlikon makes your job easier. Experience the new service dimension on our information page www.myoerlikon.com. You will benefit in every way. Secos Documents Knowledge Engineering News 18 Oerlikon Saurer Product Overview
Oerlikon Saurer Zweigniederlassung der Oerlikon Textile GmbH & Co. KG Allma Produktlinie Leonhardstrasse 19 87437 Kempten Deutschland T +49 831 688-0 F +49 831 688-321 www.saurer.oerlikontextile.com www.secos.myoerlikon.com sales-allma.saurer@oerlikon.com Oerlikon Saurer Zweigniederlassung der Oerlikon Textile GmbH & Co. KG Volkmann Produktlinie Weeserweg 60 47804 Krefeld Deutschland T +49 2151 71701 F +49 2151 717474 www.saurer.oerlikontextile.com www.secos.myoerlikon.com sales-volkmann.saurer@oerlikon.com Oerlikon Textile Inc. 8801 South Boulevard Charlotte, NC 28273 USA T +1 704 394 8111 F +1 704 393 1502 info.twisting@saurerinc.com Oerlikon Textile Far East Ltd. Room 2806 China Resources Building 26 Harbour Road Wanchai Hong Kong T +852 2866 3501 F +852 2861 2715 info.hk@oerlikon.com Saurer Textile Systems Far East Ltd. Shanghai Representative Office 48F, Intercontinental Business Center No. 100 Yutong Road Shanghai 200070 P.R. China T +86 21 5288 5888 F +86 21 5288 5926 saurer.china@oerlikon.com Allma and Volkmann 05-2012_en Subject to alterations without prior notice! Printed in Germany The copyright of this brochure remains with Oerlikon Saurer.