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OPTIMA

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Focused on your success

At Trützschler, true customer orientation means: We use our expertise,

our in part decade-old contacts and our market-leading technologies to

help you achieve your personal goals. These can be best quality, maximum

economy or first-class efficiency.

Either way, we keep our promise to do everything in our power to give you

a competitive edge in your market and to permanently expand it.

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Content

Legal disclaimer:

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technical changes for which we assume no liability. The photos and illustrations are purely informative in nature and in part show special equipment

options which do not feature in the standard scope of delivery. We provide no guarantee as to the current nature, correctness, completeness or quality of the information provided. Warranty claims for material or immaterial damage against us or the respective author based on the use or forwarding

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P2111-221_EN220307 · Agentur Brinkmann GmbH, Krefeld

6 true innovation

8 4-end OPTIMA concept

10 OPTIMA for BCF

12 MO40 Compact

14 MO40 Extended

16 TO40 Tri-colour

20 OPTIMA processes

26 OPTIMA goes digital

28 Service, maintenance and modernisation

30 Technical Center and yarn laboratory

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The experts of Trützschler Man-Made Fibers look back on experiences

gained from thousands of spinning positions delivered. Our solutions for

extruding carpet or industrial yarns are valued throughout

the world.

Decent machinery is one ingredient for successful filament production -

therefore major producers rely on our customer-made solutions. For

newcomers to the field we also provide thorough technological support.

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The quality of multi-filaments and

bobbins is decided by your raw

material, your process settings and

manufacturing conditions – and our

design choices for the OPTIMA

platform. With 4-end OPTIMA

you go for unrivalled productivity

in combination with assured

permanent high yarn quality

and long-term reliability.

We do not know what the future

holds, but the best way to predict

the future is to shape it yourself.

If you are always searching for new

ways, join us on the true way to

successful products.

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ends of BCF

spinning

delivered

Customers

worldwide

~4,000

Countries

served

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true innovation

For many people, technological progress is the further development of

an existing solution or a revolutionary design. Trützschler’s aspiration is to

open up new competitive advantages for you. We achieve this time and

again by being the first to cross technological horizons.

The resulting solutions help you to produce your quality yarns more

efficiently and of higher quality – and that is what counts.

Rieter starts business in the man-made fiber

spinning sector with winding machinery. Over

the decades thousands of spinning positions

for textile filament, carpet and industrial yarn

were delivered all over the world.

Trützschler takes over the know-how and the

employees of Swisstex, Switzerland, and creates

the Trützschler Man-Made Fibers brand. The

Winterthur location develops extrusion systems

for carpet (BCF) and industrial yarns (IDY).

1931 2012

Because we are heading in the right direction,

you have continuous tailwinds.

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The 4-end OPTIMA platform for BCF is completed

by MO40-E for high-count and TO40 for tri-colour

BCF yarns. Furthermore TEC-O40, based on the

OPTIMA platform, is introduced for manufacturing

industrial yarns.

MO40 – a powerful 4-end BCF concept with

unrivalled productivity, reliable processes and

proven components makes its entrance.

2019

2021

4-end OPTIMA concept

There is no magic involved in manufacturing top-class carpet yarns (BCF)

or industrial/technical yarns (IDY). Two parties have to work in unison to

accomplish the task. You, the producer, arrange for a constant supply of

homogeneous polymer. Not all PA6, PA66, PET, PP, PTT chips come in the

required quality. The other point is proper maintenance – keeping the plant

in good condition assures long term reliability. The rest is taken care of by

us. We developed the OPTIMA platform with the only purpose in mind to

give you the perfect tool for your success.

8 BCF and industrial yarns

The staggered arrangement of rolls

and components minimizes angles in

the yarn path.

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Layout features: • A symmetric, straight yarn

path: staggered component

arrangement minimizes turns and

angles in the yarn path

• perfect heat distribution:

homogeneuous conditions in both

the spin beam and in the drawing

zone allow for equal filament

properties both between spinning

positions and over time.

• Gentle yarn treatment by proven

components, e.g. lamella-free

texturing by HPc technology

Overall advantages are less filament

breaks and a constant high yarn

and bobbin quality resulting in low

conversion costs.

A platform for BCF and IDY

OPTIMA is a platform – and the

basis for several 4-end BCF and

IDY extrusion systems. It lays the

foundation for a successful yarn

production by minimizing stress on

the yarn.

OPTIMA for BCF

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OPTIMA is Trützschler Man-Made Fibers’ concept for manufacturing

all types of BCF carpet yarns. The market is quite segmented – and

manufacturing processes differ. Therefore we decided to offer not one

general OPTIMA machine for all needs but to develop three different

OPTIMA systems MO40-C, MO40-E and TO40.

Each system is tailored to the requirements of a specific product category.

BCF types and applications targeted by OPTIMA:

• BCF from PA6, PA66, PET, PP, PTT tailored to the requirements of one

product category

• Mono-colour yarns for woven and tufted carpets

• Tri-colour BCF yarns

• Fine yarns down to 500 dtex

• Coarse yarns up to 7.000 dtex

• Spun-dyed yarns and qualities for automotive applications

Efficient BCF production

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MO40-C

The main feature is a high flexibility

and the small footprint of just 2 x 2

meters. Thus MO40-C is unrivalled

in output delivered per square

meter – and energy consumption is

one of the lowest per kg of yarn in

the entire industry.

MO40-C: 4 ends in a small

space and suitable for lowdpf yarns

TO40: efficient tri-colour

yarn production

MO40-E: allows for both

high-count and low-dpf yarn

production

MO40-E

The most versatile OPTIMA

system. Bigger spin packs deliver

up to 1200 single filaments per

yarn end. A standard-size spin

pack with adapters is perfect

for manufacturing standard yarn

qualities.

TO40

Our choice for tri-colour BCF. As the

name implies, each multi-filament is

composed of three different colour

strands.

Compact MO40-C

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MO40-C: unrivaled productivity

4 yarn ends on a footprint of just 4 square meters. The compact 4-end

MO40-C for BCF is everything you appreciate about our machines – secure

processes, top quality yarns, low conversion costs as well as easy handling

and low maintenance.

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Polyamide BCF (PA6 and PA66)

TSAG’s started designing PA BCF

systems 4 decades ago. Especially the

DSR heated double-shell rolls and

the texturing system reflect the high

demands on absolute yarn homogeneity –

a prerequisite for premium residential,

contract and automotive applications.

Polyester BCF (PET and R-PET)

MO40 delivers homogeneous conditions

from chips processing down to winding.

All components can be adjusted

to meet the high requirements of

polyester processing. TSAG also offers

comprehensive inline recycling and

spinning solutions for post-industrial

and post-consumer R-PET BCF.

Polypropylene BCF (PP)

This cost-effective, easy to process raw

material does not take up colour in later

processing steps. Our latest generation

dosing system offers high accuracy as

well as an unbeaten flexibility in adding

pigments or masterbatches to the

extruder.

MO40

Compact

Polymer PP/PA6/PA66/

PET/R-PET/PTT

Process mono-color

Position gauge 2000 mm

N° of ends / pos 4

N° of

extruders / line 1

N° of pos / line 1 / 2

Capacity / line up to 7.5 to/d

Spin pack type top loading

Spinneret size 240 x 109 mm

N° of ends / pack 1

Max. filaments up to 700

Titer range 500 – 3600

(*6000) dtex

Dpf range 1.5 – 40 dpf

Especially soft carpets

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MO40-E: more filaments, lower dpf

The flexible system is suited for manufacturing standard, high-count and

low-dpf BCF yarns with up to 1200 single filaments per yarn end. MO40-E

is an extended, flexible system. The spin beam is designed to either house

large spin packs for high-count yarns or a combination of adapters and the

smaller MO40-C spin pack for spinning standard BCF qualities.

MO40 extended version: A bit more space but

higher functionality

With adapter: 4 ends with up to 700 single filaments

With long spin pack: 4 ends with up to 1200 single filaments

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MO40

Extended

Polymer PP/PA6/PA66/

PET/R-PET/PTT

Process mono-color

Position gauge 2500 mm

N° of ends / pos 4

N° of

extruders / line 1

N° of pos / line 1 / 2

Capacity / line up to 7.5 to/d

Spin pack type top loading

Spinneret size 401 x 109 mm

N° of ends / pack 1

Max. filaments up to 1200

Titer range 750 – 3600

(*7000) dtex

Dpf range 1.5 – 40 dpf

Fine dpf yarns for velvety carpets

The soft, velvet-like touch is

generated by extremely fine

single filaments. To produce these

delicate yarns, Trützschler relies on

the excellent melt distribution in

the spin packs, the homogenous

cooling of each single filament and

the lamella-free HPc texturing which

is gentle on the yarn and ensures

excellent crimp and crimp stability.

Our fine dpf spinning process is

stable and efficient for all types of

polymers (PP, PA6, PA66 and PET).

Tri-colour TO40

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TO40: exciting colour effects

TO40 implements the proven smartFLEX tri-colour process. smartFLEX

BCF yarns are the basis for a broad range of reproducible colour effects

in carpets. With TO40, every trend from classy mélange to contemporary

sprinkled can be met.

smartFLEX technology

Besides the standard tri-colour process Trützschler Man-Made Fibers

offers the patented smartFLEX technology for sprinkled carpets. It is easy

to handle and can be retrofitted on existing T20 systems.

classy mélange

mélange

smartFLEX – option 1

smartFLEX – option 2

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TO40

Tri-colour

Polymer PP, PA6, PET

Process tri-color

Position gauge 2500 mm

N° of ends / pos 4

N° of

extruders / line 3

N° of pos / line 2

Capacity / line up to 7.5 to/d

Spin pack type top loading

Spinneret size 3 x Ø 120 mm

N° of ends / pack 3

Max. filaments up to 3 x 200

Titer range 1000 – 3600

(*5500) dtex

Dpf range 2.5 – 28 dpf

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Extruding and spinning

At Trützschler there is no compromise on quality – all parts and processes

are designed for highest yarn qualities, efficiency and smooth running

behaviour.

Homogeneous melt

OPTIMA’s extruders ensure optimal mixing conditions. The special barrier screw

processes all common polymers such as PP, PA, PET, or PTT. All systems

feature short melt pipes to minimize melt cooling and polymer degradation.

Additionally, waste is kept low due to quick product or colour changes.

Extruder

with dosing OPTIMA processes

system

Extrusion

and melt

treatment

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Excellent filament forming

The OPTIMA spinning system

serves every requirement of the

individual polymer, the spinning

process and the conditions in the

plant. The modular design allows

for small (4-ends) and large (up to

16-ends) production units. Excellent

filtration, high throughput and

ideal flow properties – our spin

packs deliver absolutely identical

heating conditions and mechanical

treatment of the polymer melt. Thus,

the variation of the single filament

diameter is minimized. Top loading

of the rectangular packs ensures

easy and secure handling.

Perfect cooling

The cross-flow quenching units

are pulsation-free. The cooling air

temperature, relative humidity, air

velocity and profile are adjusted

according to product requirements.

The sturdy design eases assembly

and disassembly and ensures

optimal service and maintenance

conditions.

Rectangular spin pack Open quenching cabinet

Spinning

Quenching

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Drawing and texturing

Accurate drawing to the point

More than 28,000 double-shell rolls (DSR) have been delivered worldwide

up to now. They are evidence of the high performance standard. Our

double shell rolls implement the heat pipe technology which delivers the

most accurate heating profile. Moreover, DSR rolls are robust and reliable.

OPTIMA processes

Drawing

Fast and

reliable:

absolute even

roll heating

by heat pipe

technology

– even when

not placed

into an insulated box.

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Texturing

Better and long lasting crimp

OPTIMA’s texturing system consists

of our unique HPc texturing unit and

the succeeding cooling drum.

A straight yarn path from the second

duo onwards through the texturing

jet reduces stress on the yarn. The

optimum cooling drum diameter

guarantees excellent crimp fixation.

HPc textured multi-filament yarns

are bulky and distinctively even. An

extremely stable plug leads to better

crimp retention, higher uniformity and

better coverage in the carpet. Yarn

quality is both reproducible and very

consistent from position to position.

Lamella-free texturing minimizes friction on single filaments and thus

produces BCF yarns with high and unique crimp characteristics. Plug

formation in the HPc texturing unit is coupled with filament cooling to

compensate inhomogeneities and to keep yarn quality at a constant level.

Moreover, the design reduces maintenance costs due to considerably less

wear and tear on parts in contact with the yarn.

Cooling drum

Speed control by

cooling drum

Filament inlet

Hot air inlet

Plug formation

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Winding perfect bobbins

There is one characteristic marking a perfect bobbin: it can be smoothly

processed by the downstream equipment. OPTIMA relies on the proven

FW11 2-end winders to fulfill this task. The compact winder fully automatic

and features optional step precision winding to ensure perfect bobbins for

uncomplicated downstream processes. A further advantage is the high

transfer efficiency when using plastic or paper tubes – even when paper

tubes are used multiple times.

OPTIMA processes

Winding

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OPTIMA goes digital

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Control and more

The Trützschler Central Monitoring Unit (CMU) system combines all

functionalities to control the extrusion line. It’s a simple, self-guiding,

graphical user interface for easy selection and manipulation of all process

parameters. It includes language selection as well as recipe management,

sophisticated alarm functions, free selection and combination of trends

including operating data recording.

Everything in view and under control with CMU

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No longer a dream: comparing machine

performance across lines

Tracking of each yarn bobbin to its origin

My OPTIMeye – optional

available

The new Industry 4.0 package

by Trützschler Man-Made Fibers

collects and archives data from

all your Trützschler BCF and IDY

lines across multiple production

facilities. My OPTIMeye delivers all

information you need for analyzing

and optimizing your production.

You always have an overview of the

performance of your Trützschler

plants without leaving your office.

The My OPTIMeye package is

optionally available for new as well

as older machines, delivered as

early as 2006.

Trend and alarm archives, production

data and energy consumption are

made available on a passwordprotected web server. The machine

data is stored on-site and is

reachable by any device connected

to your company network.

All data can also be accessed via

OPC UA or MySQL from your ERP

system. The Trützschler Man-Made

Fibers systems can easily be

integrated into an existing digitized

production planning process for

scheduling maintenance actions

or building up a new smart supply

chain to minimize production costs.

Fit for future

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Service, maintenance and modernisation

Our extrusion systems are designed for running over decades.

Nevertheless, keeping the performance level of the first days requires

never-ending efforts. Moreover, technology advances open up new

opportunities. We offer comprehensive technical and technological

services to keep your systems successfully producing year after year.

Texturing upgrade kit HPc

Even the heart of our machines

gets better and better. The latest

version of the HPc texturing unit

let your system produce yarns with

higher uniformity, better crimp

characteristics and retention. The

upgrade also opens up the operating

range for coarse yarns up to 3,600

dtex and more. Moreover, it allows

for higher production speeds and

energy savings.

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Need help? Contact our

Service Hotline:

service.hotline@truetzschler.ch

A pro-active lifecycle management

prevents your extrusion system

from losing efficiency over time.

Choose the building blocks you

need to maintain process stability

and yarn quality:

• Original wear and spare parts - our

large stock of over 2,000 different

parts can be shipped on short

notice.

• We also offer secured parts for

your electrical systems as well as

electrical upgrades and retrofits.

• Repairs for fast rotating parts -

heat-pipe and recoating service

as well as motor overhaul for

DSR draw rolls. Chuck service

with replacement of defective

and wear parts, oil change and

balancing.

• Upgrades - for the texturing

system (see left page) as well as

for various control systems.

• Winder revamping – exchange

of inverters and control system

upgrade.

• Maintenance plans tailored to your

needs.

• EasyKits - include all parts needed

to maintain a specific component

• On site inspections- maintenance

on the spot and a detailed report

describing site performance and

recommended actions.

• Trainings on-site or in Winterthur

about basic or advanced handling

and maintenance topics.

BCF service hubs are

located in Switzerland,

Turkey, China and the

US.

Technical Center and yarn laboratory

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Shape your future!

We are at your side to support you in turning your ideas about optimized

processes and innovative products into reality. For trials in BCF and

industrial yarn the technical center of Trützschler Man-Made Fibers in

Winterthur is at your service. The entire chain of processes from polymer

to bobbin can be validated at production scale. A well-equipped laboratory

is available to conveniently evaluate yarn produced in the Technical Center

or sent-in by you.

Pilot lines

The Winterthur Technical Center hosts both a full scale extrusion system for

BCF and a line for industrial yarns. The trial lines are equipped for spinning

PP, PA6, PA66, PET and PTT yarns. We will find the optimal arrangement

and parameter settings of the system‘s components in regard to your

requirements. Our experts will be pleased to assist you with their profound

knowledge and expertise.

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Yarn and polymer laboratory

Yarn samples are conditioned in

TSAG’s laboratory for at least 8

hours at 23 ± 2 °C and 65 ± 5 %

of relative humidity. Properties

determined later on are yarn count,

number of broken filaments and

loops, tenacity and elongation

at break, thermal fatigue, hot air

shrinkage, crimp in boiling water,

spin finish pick up and filament

cross section.

In respect to polymer quality

assessments our facility is

quipped with a Karl-Fisher-Titrator

to measure the polymer’s exact

moisture content at the extruder

inlet. With our partners it is

also possible to conduct more

sophisticated analyses.

Fiber preparation installations: Bale openers · Mixers · Cleaners /

Openers · Foreign part separators · Dust separators · Tuft blenders

Waste cleaners | Cards | Draw frames | Combing machines | Digital

Solutions: My Mill · My Production App · My Wires App

Bale openers / Mixers | Card feeders | Cards / Crosslappers

Wet laying lines | Hydroentangling, needling, thermo- and chemical

bonding lines | Finishing, drying, winding, slitting machinery

Filament lines: Carpet yarns (BCF) · Industrial yarns

Metallic wires: Cards · Cards long staple · Cards Nonwovens

Rotor spinning | Flat tops | Fillets | Carding segments

Service machines | My Wires App | Service 24 / 7

www.truetzschler.com

Filament lines: Carpet yarns (BCF) · Industrial yarns

Metallic wires: Cards · Cards long staple · Cards Nonwovens

Rotor spinning | Flat tops | Fillets | Carding segments

Service machines | My Wires App | Service 24 / 7