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. 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.

MO40-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.

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.

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.