| Welcome to IN-LINE with FI-TECH
 Welcome to the first edition of In-Line with Fi-Tech of the new millennium! While a lot of us spent months and years preparing for Y2K, its passing was rather anti-climactic. Maybe it was the preparation and planning that made it such a non-event.
While the Y2K bug never really developed, other challenges lay before our industry: Asian Imports, a strong dollar affecting the export market, and a consolidating customer group. Using innovation, automation, and partnership our industry can continue to thrive in North America by supplying our customers’ products that are unique, consistent in quality, delivered just in time, and with added value.
Fi-Tech is continually looking for companies with innovative products that will improve our customers’ products or process. We are pleased to announce our association with MAB of Genestrerio, Switzerland and Idrosistem of Bassano del grappa, Italy. As of January 1, MAB appointed Fi-Tech as the exclusive representative for MAB dense-pulse phase conveying equipment for the U.S. and Canada. Fi-Tech has represented MAB in Mexico since 1997. Please refer to the article on MAB in this issue for more details on MAB’s pneumatic conveying systems.
In addition, Fi-Tech is now marketing the Water filtration Systems of Idrosistem for application in the hydroentanglement process. Idrosistem can deliver the entire system for water filtration including the flotation separation, sand filters, piping, valves, and controls used in the hydroentangling process. The heart of their technology is in the back flushable sand filters that are installed upstream of the safety filters. The sand filters remove all suspended solids and extend the life of the safety filters considerably.
Also, we are pleased to announce that beginning April 17, Fi-Tech will offer field service on most Enka tecnica testing and measuring equipment. Please see the article in this issue for more details.
Fi-Tech representatives will be at a number of exhibitions in the coming months (see the calendar of events). We hope that we will have a chance to introduce MAB and Idrosistem to you or discuss how our other suppliers’ products can help improve your product or process.
As a final note, I would like to welcome Maggie Mabbitt to Fi-Tech. She will be a Sales Assistant to Chris and Jim.
Todd L. Bassett
Cason PP Spinning Plants
Announcing the arrival of the long awaited ECO 70 compact polypropylene spinning plant from Cason s.p.a. With the capabilities of producing fine denier POY, FDY, and FDY high tenacity Polypropylene, Cason’s newest product line is ready for the world market. As a matter of fact, they have already sold their first spinning plants and we are happy to report that the first is running successfully.
Fine denier Polypropylene fabrics are part of a growing market, where uses can be found in the sporting wear and undergarment markets. Its wicking qualities enable its users to stay dry by releasing body humidity with extreme efficiency.
The ECO 70 is a flexible plant, where customers are able to produce yarns of different deniers and colors all on the same plant. Cason has engineered their own extruder and spin heads and manufactures them internally. The lines of course include their own entangling devices, yarn cutters, and control system. Winders are available from leading manufacturers in either a manual, fully automatic, single or multi-thread configuration.
The ECO 70 is able to produce 70 denier, POY yarn (after texturing) in 40 filaments and is capable of producing up to 3000 denier. A 70 denier, 60 filament configuration will be available in the near future.
In addition to delivering a quality product, Cason provides itself on being able to support the customer from start up throughout the life of the plant. Should the ECO 70 be of interest to you or your company, please feel free to give us a call at Fi-Tech. One of our Sales Engineers would be more than happy to discuss your requirements with you.
MAB Expands Relationship with
Fi-Tech
As of January 1, 2000, MAB – Switzerland has appointed Fi-Tech as the exclusive representative for MAB dense-pulse phase conveying equipment for the US and Canada. Fi-Tech’s sister office in San Luis Potosi, Mexico has represented MAB in the Mexican market since December 1997. MAB is a pioneer in the field of low velocity, dense-pulse phase pneumatic conveying systems. Base on R&D efforts started in 1970 and continuing today, MAB PULSVEYOR technology has now been installed in more than 32 countries providing effective solutions to complex conveying problems with over 200 different materials. Recently, MAB introduced the ROTOVEYOR for dense phase low velocity pneumatic conveying using high-pressure rotary valves. The success of the PULSVEYOR and ROTOVEYOR is due to its ability to handle delicate products, such as plastic pellets, without any degradation of the product. In the case of PET, PA and PP pellets, the conveying system produces no fines, dust or "angel hairs" even over long conveying distances.
 The PULSVEYOR based system (see Diagram 1) consists of a pressure tank (1) equipped with specially designed gate valves (2 and 3). These valves provide an excellent seal even in the presence of granular solids. Product in conveyed by gravity by way of the gate valve (2) into chamber (1). Compressed air or other gas (4) is introduced into the PULSVEYOR at metered flow and pressure so cushions of gas are placed between plugs of material to be conveyed. The result is a low velocity uniform flow of material. Key advantages are:
- High Flow Rates at low velocity with low energy and gas consumption
- No production of dust, fines or "angel hairs"
- Conveying distances in excess of 1000m with one unit
- No wear to pipes, fittings and valves
- Low generation of static electricity
- Low noise level
The ROTOVEYOR based system (see Diagram 2) improves upon the PULSVEYOR by further reducing the air/gas consumption by using higher air pressure. The heart of this system is the specially designed high pressure rotary valve (2) which feeds the product from the feed hopper (1) at high pressure (1.5-2.8 bar-g), minimizes gas leakage, does not jam on product and operates at high efficiency. The conveying gas can be fed from a dedicated compressor of from the plant network. The MAB gas control system (4) regulates flow and pressure of the compressed gas in either case. The injection system (3) produces the low velocity plugs cushioned by gas. In addition to the PULSVEYOR advantages, the ROTOVEYOR uses less gas and lower conveying velocity for capacities up to 40 tons/hr.
Along with the above key components, MAB also manufactures special diverter valves, special gate valves with inflatable seals, and de-dusting systems for separation of dust and streamers from pellets. In addition, MAB produces complete continuous drying systems for nylon 6.6 and for amorphous polyester, crystallizers and de-duster/coolers for PET chips. Along with in-house engineering capability, MAB designs and builds turnkey conveying solutions that are proven under strenuous 24 hour/day operating conditions with long on stream life.
Give us a call today to help solve your conveying problems. We welcome your ideas and suggestions. Our experts will study and confirm the best solution for you.
Enka tecnica Components
It is well known that Enka tecnica provides the Synthetic Fibers and Nonwovens Industries with high quality spinnerets and technical components and testing devices. Many of these components help the fiber producer make a better product or allow him to test the fiber to see that it meets quality levels.
 The Temptec Temperature Recorder allows the fiber producer to measure the actual surface temperature of spinnerets and heated rolls. Although these temperatures are managed by appropriate regulating systems and monitored by process control systems, there is still a need to determine precise surface temperature by a single test. The Temptec temperature recorder is composed of a temperature feeler for spinnerets and another one for rotating rollers. The maximum temperature reading for the spinneret feeler is 350º C. The accuracy is ±0.5º C. The feeler for the heated rollers has a maximum temperature reading of 350º C and an accuracy of ±1-3º C. A digital thermometer with an integrated printer is included with the unit. Replaceable thermocouple strips are available from our stock in Richmond, VA.
The Tensoscan® Automatic Warp Tension Monitoring Device is designed to monitor the warping tension of the individual filaments in a warp sheet. An electrically driven measuring carriage mounted on two yarn guide bars travels at constant speed across the full width of the warp. As it moves back and forth across the yarn sheet, the probe senses tension in each yarn. If tension is above or below preset values, a lamp flashes and the carriage stops at the end in question. After the yarn tension is fixed, a reset button is pushed to resume scanning. It is also possible to integrate the threshold switch with the stopping arrangement of the warping machine so that when a problem is detected, the warping unit stops with the Tensoscan unit. The Tensoscan scans at a rate of 0.4 meters per minute. In order for both the high and low tension settings to work, the individual filaments must be separated by 1.4 mm. For high tension readings only, the filaments must be at least 0.7 mm apart. A high-speed recorder can be hooked up to the device so that uniformity across the warp can be charted and analyzed.
 The Itemat Lab TSI is designed to test the number, distribution, and stability (or load bearing capacity) of yarn interlaces. The number and distribution of interlaces is tested on the Itemat according to a thickness-scanning principal. This means that non-interlaced and twistless filament yarns can be flattened with only slight mechanical pressure. However, with the same pressure, the interlaced nodes maintain their shape. The Itemat scanning head consists of a small rigid plate and a spring-loaded, ceramic-coated pin. The yarn passes between these two bodies at constant speed. When encountering an interlace point, the movable pin will be deflected. In the absence of such an interlace, the pin will press the yarn together. This pin movement is transformed into an electrical signal, which is processed by a personal computer. The software program converts this signal into usable data.
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Enka tecnica Components (continued..)
The Lab TSI unit also tests the stability of interlaces. The yarn is strung up on small godet rolls and measured before the godet rolls stretch it. After the first measurement, the yarn is stretched, and then the exact same section of yarn is measured again. The measurement signals are processed and compared so that the user can determine the stability of the nodes. This is the best way to test for interlace stability. The Itemat Lab TSI is a critical laboratory device for any filament producer where node numbers, distribution, and stability are critical to down stream processing.
In May, Enka tecnica is expected to release its new YarnScan Online Sensor. This sensing unit will be a small, very robust unit with a self-cleaning sensor head. The unit will be able to give accurate readings for yarn denier, entanglement node uniformity, and spin finish levels using a special electrical induction method. More information for this new development will be available soon.
ATME I – 2000
American Textile Machinery Exhibition-International
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It’s not too early to begin planning your visit to the ATME I-2000, coming up this fall in Greenville, SC. As with past exhibitions, the available rooms in the surrounding area will be booked up quickly, so now is the time to make your reservations. The exhibition dates are from October 23 through October 27.
Fi-Tech will be exhibiting with 11 principals in hall D of the Palmetto Exhibition Center, with over 3,500 square feet of exhibit space. Our booth will be located between aisles 2500 and 2600, just to the left of the entrance for pre-registered attendees. There will be equipment on display from Cason and MOVEngineering, as well as experts in all facets of fiber manufacturing from companies such as Lurgi-Zimmer, MAB, Enka tecnica, Autefa, Burckhardt, Sikoplast, Zentes Unitex, and Reifenhauser.
Don’t delay! Make the all today. To get information on registration and reservations, contact the Greenville Convention and Visitors Bureau at 864-421-0000, or the ATME-I at 864-233-2562. You’ll be glad you attended!
Enka tecnica Service
 In response to our customers’ request regarding Enka tecnica components and testing equipment, Fi-Tech will offer Field Service beginning April 17, 2000 for Fraytec, Tensoscan, Fibertec, Itemat and YarnScan. Randy Wise, a Fi-Tech employee for approximately 2 years, will be the Field Service Technician for Enka tecnica and is currently undergoing training on set-up, calibration and trouble shooting of general components and testing equipment.
Helge Pietzonka
 It is with great sorrow that we announce the death of our associate and friend, Helge Pietzonka, Area Sales Manager for Enka tecnica. Helge was seriously injured in an auto accident on the way from his home to work on February 11. He died several days later in a hospital in Cologne.
Our thoughts and sympathies are with his family, his girl-friend and his loved ones.
We will sorely miss Helge’s fighting spirit which motivated us all to achieve our best.
Wetzel Calender Roll Engraving Technologies for the Nonwovens Industry
Wetzel GmbH of Grenzach-Wyhlen, Germany (formerly known in the Nonwovens Industry as Casaretto) has the unique distinction of being the only roll engraver in the world that possesses all known engraving technologies. In addition, Wetzel also has several exclusive engraving technologies that no other roll engraver has. This means that Wetzel can select the best engraving technology, or combination of technologies, for your particular roll-engraving requirement.
For Engraving thermobond calender rolls for the Nonwovens Industry, either chemical etching, mill-and-die, or pressless milling is normally used. Each technology offers its own set of advantages.
Example of pattern made with chemical etching.
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Wetzel’s chemical etching technology is more-properly termed "laser chemical etching," because a laser is used instead of the more traditional photo-developing method. The Pattern to be etched is first loaded into a computer in digital format. Next, the roll surface is painted with a chemical-resistant lacquer. The laser, which is controlled by the computer, burns out areas of the lacquer coating according to the pattern in the computer. The exposed areas of the lacquer coating are then chemically etched in an acid bath.
Chemical etching is fast and least expensive technology. Almost any steel roll can be etched, regardless of hardness. The maximum depth that can be chemically etched depends on the relationship between the depth and width of the design. There is generally a 2:1 ratio between the width and the depth.
There is practically no limit to the designs or shapes that can be etched. However, it is difficult to consistently etch two or more rolls with the same, identical pattern. There will always be small variations.
Etching also produces a rough surface, and there may be some undercuts. (In general, chemical etching is used for two-dimensional patterns.) If deep, narrow profiles are needed, then it may be possible to etch the profile in multiple steps.
Example of pattern made with mill-and-die.
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Mill-and-die is a cold forging process in which a rotating hardened tool is pressed against the surface of the steel roll and deforms the metal into the shape of the tool. The patterned tool rotating against the embossed surface of the roll resembles two inter-meshing gears. The minimum flank angle that can be produced with mill-and-die is 22º, the same as the minimum tooth angle that is needed for gear clearance. Almost any 2-dimensional or 3-dimensional pattern can be produced with mill-and-die. The only limiting factors are the 22º minimum flank angle, every round pattern must have a defined radius. The maximum engraving depth is about 2.5mm.
Because mill-and-die is a cold forging process and the steel must be able to "flow" into the cavity of the tool, it can only be used on steel with a hardness no greater than 40 HRc. If required, the roll can be hardened after engraving, up to 56-58 HRc with nitride hardening. Different rolls engraved with the same pattern will be consistent with close to 100% reproduction, because the same master tool is used. The tooling cost for the die can be expensive if the pattern, or tooling, does not already exist. Also, the production time can be quite long, because the tool is narrow and must slowly traverse down the length of the roll.
One of the drawbacks of mill-and-die is that very high pressure must be applied against the tool in order to deform the steel surface of the roll. When the tool is halfway down the length of the roll, this very high pressure in the middle of the roll can cause the roll to deflect and cause a variation in the engraved pattern. The problem can be overcome by using an engraving technology exclusive to Wetzel called "pressless milling." This process does not use high pressure against the roll or a rotating die. The minimum flank angle for pressless milling is 4º.
Pressless milling overcomes another drawback of mill-and-die in terms of what happens to the steel as it fills the cavity in the tool. The 22º minimum flank angle means that the negative image in the tool is trapezoidal shaped.
Example of pin profile made with pressless milling
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As the steel deforms and fills up the trapezoidal cavity of the tool, the steel flows faster on the sides of the cavity than in the middle. This is because the sides become narrower as the cavity is pressed deeper into the steel roll. The result is bonding pins with uneven stresses in the steel.
This problem of uneven stresses is avoided with pressless milling. Pressless milling can be used to engrave bonding pins with two flank angles, such as 4º and 30º. The 30º flank angle at the
Pressless milling pattern defined by intersecting straight lines.
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base gives strength to the bonding pin, and the 4º angle at the top allows the roll to be re-ground several times with only a minor increase in the bonding area of the pin surface. Pressless milling is limited to patterns that are defined by intersecting straight lines, such as rhombuses and diamonds.
Because pressless milling is not a cold forging process, it is not limited by the hardness of the steel to the same extent as mill-and-die. In fact, it can be used to engrave pre-hardened steel rolls that are induction hardened up to 52 HRc. This is discussed in the next article.
New Wetzel Engraving Development for High Speed Calenders
As the speeds of nonwovens lines increase, so does the need to increase the hardening depth of the engraved calender rolls. Engraved calender rolls have typically been gas nitride hardened after engraving. The maximum depth of gas nitride hardening is only .6 mm. This results in a "case hardened" steel roll which may have a surface hardness of 56 HRc, but the metal under the thin layer of nitride hardening can be as soft as 24 HRc. If any foreign matter such as a metal object or even a large polymer drip passes through the calender nip, the hardened pins can be pressed into the soft base metal below. Even if the hardened pins are not damaged, they can be pressed into the soft base metal far enough so as not to make good contact with the nonwoven fabric. The result is a nonwoven fabric with uneven bonding.
Induction hardening is an alternative to gas nitride hardening which can achieve a hardness depth up to 6 mm. Nonwoven fabric producers normally expect to be able to grind off an old engraving and have the calender roll re-engraved with a new engraving at least 3 or 4 times on the same roll. However, with induction hardening the surface is already hardened to a depth of 6 mm. This means the new engraving must be made into a surface that is already hardened.
Wetzel is now able to offer its proprietary pressless milling to engrave rolls pre-hardened by induction hardening. Wetzel can use its pressless milling to engrave into an induction hardened roll with a hardness up to 52 HRc. This new engraving development allows engraved calender rolls to have a greater depth of harness, which is especially needed for higher line speeds. Also, there is less possibility of accidental damage to the engraved surface. This means less down time for maintenance and roll repair. In addition, the roll can be re-engraved several times without the need for additional hardening after each re-engraving.
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