Oerlikon Manmade Fibers Segment

From Melt to Yarn

2nd International Polyester Conference,
Indian Polyester 2014

Atul Vaidya
General Manager - Sales

Oerlikon Manmade Fibers Segment

From Melt to Yarn

Oerlikon Manmade Fibers Segment 5.8.2014

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/

Locations: 5 production sites

in 4 countries (11 sites overall)

Employees/
Production

Productlines/
Customers

Oerlikon Manmade Fibers Segment 5.8.2014

No of Employees: 2500

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

Strong Position in Volume Business with

Growth Potential in Plant Engineering & Services
Spinning Plants

POY, FDY, IDY spinning

plants produce endless
multifilament yarn for textile
and technical applications

Texturing Machines

DTY texturing machines

crimp the pre-oriented yarn
(POY) to give a cotton-like
touch

Customer Support: Partnering for Performance

Original Parts
myOerlikon.com
Logistics
Warehousing
Installation
Training
Surface & Material Testing Lab
R&D Center

Oerlikon Manmade Fibers Segment 5.8.2014

BCF Carpet/Tape/Mono

BCF plants produce

endless multifilament yarn
for home textile and carpet
applications
Tape & Monofilament

Plant Engineering

Continuous
Polycondensation (CP)
Staple Fiber Plants (SF)
Spunlaid, Meltblown and
Airlaid solutions

Oerlikon Manmade Fibers Segment at home

in growth markets and applications
Other applications:
Outer wear
Sports wear
Hosiery & socks
Protective apparel

Apparel

Other applications:
Seat covers
Upholstering

Home
textiles

Technical
textiles
(Filament)

Technical
textiles
(Nonwovens)

Oerlikon Manmade Fibers Segment 5.8.2014

Other applications:
(Seat) Belts
Tarpaulin
Ropes
Nets
Sewing threads
Other applications:
Agrotextiles
Medical

Oerlikon Manmade Fibers covers two

Processes of the entire Value Production Chain
Petrochemicals

Raw material

PTA
MEG

Caprolactam

Melt

Yarn

Raw fabric

Polymer
Processing
(CP)

Spinning

Textile
Processing

Polycondensation

Polymerization

POY/DTY
FDY
IDY
BCF

Staple fiber
Nonwoven

Knitting

Treated
fabric

End product

Application

Finishing

Product
Make-up

Retail &
Distribution

Dying and
Finishing

Interior
Textiles

Printing

Technical
Textiles

Weaving

Coating/
Laminating

Nonwovens
Garments
Carpets

Oerlikon Manmade Fibers Segment 5.8.2014

Retailer
Merchant &
Whole-sale
Con-tractor
& Supplier

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

Oerlikon Manmade Fibers Segment 5.8.2014

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

Oerlikon Manmade Fibers Segment 5.8.2014

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

Oerlikon Manmade Fibers Segment 5.8.2014

Solution

Energy-saving,
environmentally-friendly
cost-efficient process
Compact and ergonomic
draw field designed for
excellent performance

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

Oerlikon Manmade Fibers Segment 5.8.2014

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

Oerlikon Manmade Fibers Segment 5.8.2014

Energy-saving and efficient process

Compact and ergonomic draw field for
excellent performance and lowest
OPEX values
Easy-to-handle process

Introduction
WINGS FDY machines in the market

> 2,000 spinning positions delivered until 2013

> 1,500 spinning positions to be delivered in 2014 and

2015

3,500 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

Oerlikon Manmade Fibers Segment 5.8.2014

The manmade fiber market

OPEX determine the success of commodities
Energy
reduction
e-save

Reduced CO2 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

Oerlikon Manmade Fibers Segment 5.8.2014

2-Step Staple Fiber Plant Characteristics and Advantages

Main
Characteristics

Advantages

Page 14

Highest fiber quality

Fine titer staple fibers
Highest Capacity

Spinning speed:
Drawing speed:
Capacity:
Titer range:

600 - 2,500 m/min

100 - 300 m/min
up to 300 tons/day
0.9 - 70 dtex

Key Benefits
Full supply of value chain
Low OPEX

Full supply of
value chain

Approved
quality

Worldwide
Service Network

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

Oerlikon Manmade Fibers Segment 5.8.2014

Experienced
Execution

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.

Oerlikon Manmade Fibers Segment 5.8.2014

Key Benefit
Worldwide service network
Low OPEX

Full supply of
value chain

Approved
quality

Worldwide
Service Network

Experienced
Execution

Technical Service
Germany

World wide service network

24-h emergency support

Remscheid
Neumunster
Chemnitz

China

Turkey

USA

Service stations close to you

Charlotte, NC

India

Professional services,
on-site and remote

Mumbai
Vadodara

Beijing
Shanghai
Suzhou
Wuxi
Taiwan
Hong Kong

Indonesia

24/7 service hotline

Speaking your language

Oerlikon Manmade Fibers Segment 5.8.2014

Key Benefits
Experienced Execution
Low OPEX

Full supply of
value chain

Approved
quality

Reliable and stable business partner

Top references

Oerlikon Manmade Fibers Segment 5.8.2014

Worldwide
Service Network

Experienced
Execution

Key Benefits
Experienced Execution
Low OPEX

Full supply of
value chain

Approved
quality

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 300 mto/d, semi dull
commissioning in 2008

Bottle Grade, 2012 (India)

EPC contract
1 line 600 mto/d
1 line 700 mto/d SSP

including utilities

Oerlikon Manmade Fibers Segment 5.8.2014

Worldwide
Service network

Experienced
Execution

Key Benefits
Experienced Execution
Low OPEX

Full supply of
value chain

Approved
quality

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 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 600 mto/d
2 lines 700 mto/d SSP

Commissioning of line 1 in 2013, line 2 in 2014

including utilities
Oerlikon Manmade Fibers Segment 5.8.2014

Worldwide
Service network

Experienced
Execution

Thank you.

Oerlikon Manmade Fibers Segment 5.8.2014