CABLECORDER CC4 CABLECORDER CC3. NUMBER ONE FOR TEXTILES IN TIRES. TIRE CORD.

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1 CABLECORDER CABLECORDER. NUMBER ONE FOR TEXTILES IN TIRES. TIRE CORD. EN

2 Competence in Twisting. Twisting and cabling systems Allma in Kempten and Volkmann in Krefeld form the Allma Volkmann Business Unit in the Saurer Group. Allma and Volkmann are leaders in the global market for twisting and cabling technology. For decades, Allma has been constantly setting milestones in the production of twisting and cabling machines. As innovation leader we offer world leading and energy efficient technology for tire cord and industrial yarns. As supplier for complete solutions and over-all concepts we enjoy an excellent reputation. Our products are the result of a wide experience built over many generations, paired with today s knowledge for the textile future. Textile tradition and up-to-date technologies merge to a symbiosis of know-how, quality and product reliability. It is our target to constantly develop innovative and economically interesting products on highest level for the benefit of our customers. A technical/textile technological support in combination with high customer intimacy on the basis of our worldwide linked service organization as well as a speedy and customer focused supply with original parts are also a significant centerpiece of our core competencies.

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4 CableCorder The production of tire cord is a very energy-intensive production process. Energy costs represent the highest proportion of costs in the whole process. The direct cabling machine Allma CableCorder allows for an extremely energy efficient and highly economical production of high quality tire cord. The conferment of the Tire Technology Award for Innovation and Excellence 2011 in the category Tire Industry Supplier of the Year underlines the future-oriented technology of the CableCorder. The energy saving miracle CableCorder revolutionizes cabling ff Up to 50% reduced energy consumption ff Up to 50% reduced heat load reduced air conditioning costs ff Up to 50% fewer thread breaks fewer short packages ff Up to 5 db(a) reduced noise level and pleasant indoor climate ff High material flexibility thanks to optimized and especially treated surfaces ff High process reliability through online monitoring ff Low maintenance due to high quality components ff More than 1700 Allma CableCorders sold Worldwide customer support Market leader with the greatest experience 4 CABLECORDER CABLECORDER

5 E³ Triple Added Value We aim to provide our customers with innovative products that make a difference in their production and profitability. The passion for our products drives our innovation. By focusing on our customers requirements and combined with Saurer s philosophy of innovation and sustainability, triple added value has been created. USD/kg 0,180 0,160 0,140 0,120 0,100 0,080 0,060 0, % -30 % -23 % -30 % Energy ffup to 50 % lower energy consumption through patented technology 0,020 0,000 India Indonesia Korea China Energy costs Space costs Labour costs Waste costs Economics ffup to 40 % reduction of twisting costs thanks to energy savings ffup to 50 % fewer thread breaks ffup to 50 % less waste heat and air conditioning costs Cost savings Asia 0,400 0, % 0,300 Ergonomics ffup to 5 db(a) reduced noise level ffreduced operating times through easy handling USD/kg 0,250 0,200 0, % -27 % 0, % 0,050 0,000 Western Europe Estern Europe North America South America Energy costs Space costs Labour costs Waste costs Cost savings Europe and America CABLECORDER CABLECORDER 5

6 CableCorder Pioneering energy saving technology Cutting-edge technologies are the key factor for E³. Thanks to the innovative outer yarn feed device, the outer yarn is controlled and the yarn balloon thus reduced to a possible minimum. Since mainly the yarn balloon is responsible for the machine s energy consumption, the considerably smaller balloon compared with conventional cabling machines allows for reducing the energy consumption by up to 50%. CableCorder offers triple added value Energy costs can be up to 50% of overall production costs of tire cord, depending on the location, and therefore this innovation makes a considerable contribution to cost reduction and thus aiding economic viability and competitiveness. A slim yarn balloon reduces the noise level enormously compared with conventional cabling machines. This makes a strong contribution to enhancing the machine ergonomics. The active delivery of the balloon yarn reduces the yarn break rate by up to 50%. Patented technology The technology developed by Allma engineers allows for energy savings on the CableCorder of up to 50% compared with conventional cabling. The system has been patented in the main markets and may be exclusively used by Allma customers. 6 CABLECORDER CABLECORDER

7 CableCorder CableCorder Machine cross section Feed package and reserve package 8 Thread balloon 14 4-hinge package cradle 2 Pretensioner in creel 9 Inner yarn tensioner 15 Suction unit 3 Outer yarn tensioner () 10 Cord Regulator 16 Conveyor belt 4 Outer yarn delivery system () 11 Capstan with online monitoring 17 Yarn tensioner 5 Air threading 12 Traverse motion / Winding roller 18 Balloon thread guide 6 Motor spindle 13 Twist package 19 Package cradle absorption 7 Spindle pot / Feed package CABLECORDER CABLECORDER 7

8 Allma drive and control system for highest productivity The CableCorder drive and control system enables the economical production of top quality tire cord. The modern design of the user interface ensures an effective and safe handling of the machine. Innovation guaranteed As a market and innovation leader, we are committed to offer our customers solutions which enable them to meet the challenges of the future and guarantee their success. Increasing raw material and energy prices are one of these challenges. The requirement to be met by you is to economically manufacture a top-quality product. The requirement to be met by us is to make the right means of production available to you. With the CableCorder by Allma our customers are well prepared to meet the challenges of the future. 50 Success guaranteed Delivery speeds infinitely variable up to 60 m/min, large feed package and twist package weights of up to 15 kg ensure maximum productivity. The new technology allows you to set the energy savings of up to 50 % directly at the user-friendly touchscreen! 8 CABLECORDER CABLECORDER

9 Cooling of the electronic system The CableCorder can be equipped with optional two air/water heat exchangers for cooling the electronic control cabinet. Alternatively, air/refrigerant heat exchangers can be used. Controlled machine stop Controlled machine stop and restart in case of power failure through the use of an uninterrupted power supply UPS (additional device). No productivity loss, no quality loss. Constant yarn and package quality thanks to completely reproducible production data Your customers want to rely on the agreed twisting and package quality. Therefore, you can easily and centrally set and save all production data on the CableCorder screen. Thus each lot can be reproduced with identical quality at any time. Furthermore you can save any desired number of lots and transfer the data from one CableCorder to another. Cabling and two-for-one twisting on one machine The CableCorder combines the processes of cabling and two-for-one twisting in an intelligent way. Symmetrical 2-ply tire cord constructions are, as usual, economically cabled in top quality. On CableCorder equipped with the two-for-one package (additional device) you can economically process single yarns as well as symmetrical and asymmetrical 2-ply and 3-ply yarns. In this version, delivery speeds are infinitely variable up to 120 m/min. Two completely independently controlled machine sides underline the flexibility of the Cable Corder. CABLECORDER CABLECORDER 9

10 Spindle design for optimal twisting quality -- Robust and backlash-free 4-hinge package cradle --Perfect package formation for optimal unwinding properties -- Constant winding tension, centrally adjustable -- Uniform contact pressure of package during package build-up -- Assured yarn path with all kinds of yarns --Reduced tension and twist differences --Simplified monitoring and exact reproducibility --Simultaneous opening of all flaps for feed package change --Easy handling of twisting position --Clearly arranged yarn path --Considerable reduction of operating times -- Top product quality thanks to online monitoring of yarn tension at every twisting position -- Minimum length differences of single yarns as a result of superior Cord Regulator technology - - Maximum speed of 11,000 rpm and delivery speed of 60 m/min for highest production 10 CABLECORDER CABLECORDER

11 Allma Number One in the world for industrial yarns Our customers expect products from us that clearly distinguish them from their competitors. Tire cord is a safety product and thus is bound to meet the highest quality demands. The CableCorder heralds a new era with regard to the economical production of top quality tire cord. With its range of technical twisting machines, Allma offers you a product range which gives you the competitive edge over your competitors and helps you gain and maintain the lead. Energy-saving miracle An intervention in the process by means of the new outer yarn delivery system on CableCorder allows the balloon size to be optimised. The ingenious solution offers an energy saving of up to 50 %. Fewer thread breaks The outer yarn delivery system on CableCorder releases caught yarns thus ensuring troublefree unwinding. As a result, the already very low number of thread breaks is further reduced by up to 50 %. High precision The CableCorder inner yarn tensioner works highly precisely thanks to capstan system. Settings are reproducible at any time and can be quickly and easily transferred to all spindles. High process reliability Online monitoring of the yarn tension (EasyGuard) at every twisting position ensures maximum product quality at any time. High cord quality The Cord Regulator ensures equal lengths of the inner and outer yarns in the cord thus assuring high cord quality. The Cord Regulator offers high levelling and low total yarn tension. CABLECORDER CABLECORDER 11

12 Benchmark in safety, quality and economic efficiency High efficiency Thanks to the outer yarn delivery system, the efficiency is tremendously increased: The energy consumption is reduced by up to 50 % and analogous to energy saving, waste heat has the same value. Further, the number of thread breaks is lowered by 50 %. USD/kg 0,180 0,160 0,140 0,120 0,100 0, % -30 % -23 % -30 % High material flexibility It s the many small details which make the big difference in highperformance twisting machines. More than 1700 Cable Corders in the market have taught us what is important in the manufacture of technical textiles. The CableCorder is suited to cabling PA, PES, PES-HMLS, PEN and Lyocell in a count range of 940 dtex to 2520 dtex and is the only machine in the world market that is acknowledged for processing aramid and rayon. Top yarn quality is ensured by optimised surfaces, specially-treated yarn guiding elements and ingenious machine design. 0,060 0,040 0,020 0,000 Fig. Cost savings Asia (savings in air conditioning costs not considered) 0,400 India Indonesia Korea China Energy costs Space costs Labour costs Waste costs High production flexibility In the combined version with two-for-one package (additional device), the CableCorder with its new spindle design allows for processing of symmetrical 2-ply tire cord as well as single and 3-ply yarns on the same machine. With only a few actions, the Cable- Corder can be changed from cabling to two-for-one twisting. User friendliness Loading edge of the flap makes loading of the spindle pot package much easier. Substantially reduced noise level thanks to the yarn balloon being optimised by the outer yarn delivery system. USD/kg 0,350 0,300 0,250 0,200 0,150 0,100 0,050 0, % -27 % -15 % -27 % Western Europe Estern Europe North America South America Energy costs Space costs Labour costs Waste costs Low maintenance requirements Regreasable Cord Regulator and spindle motors ensure a long service life. The solid machine design and high-quality components provide a long machine life with minimum maintenance requirements. Fig. Cost savings Europe and America (savings in air conditioning costs not considered) Low waste Constant and independent monitoring of spindle speed, winding speed and produced cord length at every spindle ensures high package quality and minimises waste also in subsequent processes. 12 CABLECORDER CABLECORDER

13 Additional devices CordGuard The CordGuard measures the total yarn tension, recognises yarn breakages, continuously monitors the twisting process, detects mechanical defects at the inner yarn tensioner, Cord Regulator and capstan as well as threading errors of the operator and unwinding problems at the feed packages. HiLo creel The HiLo creel is adjustable in height and gives the user an ergonomically optimum creeling position. Suction of hot air Extraction of heat from the spindle area provides optimised climate thus ensuring high-quality yarns. A positive side effect of this is a reduced noise level. The CableCorder design and the highly improved energy balance allow for a considerably reduced air-conditioning system. Two-for-one package The newly designed two-for-one package permits processing of single yarns as well as symmetrical and asymmetrical 2-ply and 3-ply yarns on your CableCorder. Noise abatement Noise-absorbent mats for further reducing the noise level. Equipment for processing rayon and aramid Special finish and surfaces of yarn guiding elements for gentle treatment of the yarn when processing materials such as aramid and rayon. Clutchable capstan For individually stopping the capstan at each spindle to avoid yarn laps in case of long downtimes. CABLECORDER CABLECORDER 13

14 CableCorder Machine dimensions L 1420 gauges 450 and gauge gauge CABLECORDER CABLECORDER

15 CableCorder Technical and textile data CableCorder Gauge 450 Gauge 500 Spindle sizes mm Ø/traverse 205/10, 230/10, 230/12, 230/10, 230/12, 250/10, 250/10, 250/12 (205/12 please consult us) 250/12, 290/10, 290/12 Number of spindles max Spindle speed rpm max spindle 205, 230, 250 and spindle 290 Range of twists tpm Direction of twist S or Z Delivery speed m/min Materials PA, PES, AR, CV, (PES-HMLS, AR and CV with additional device) Range of counts dtex x Additional devices: Power line filter, interface for production data acquisition, HiLo creel, remote diagnostics, air/water or air/refrigerant heat exchanger, noise abatement, suction upwards or downwards, thread reserve, tension meter, stroboscope, splicer, equipment for processing rayon and aramid, CordGuard, clutchable capstan, UPS Feed packages Ø 205 mm Ø 230 mm Ø 250 mm Ø 290 mm kg kg kg kg Traverse 10 PA 5.0 PA 7.0 PA 8.5 PA 12.2 PES 6.0 PES 8.0 PES 9.8 PES 14.1 CV 6.2 CV 8.5 CV 10.4 CV 14.7 AR 6.2 AR 8.5 AR 10.4 AR 14.7 Traverse 12 PA 8.2 PA 10.2 PA 14.5 PES 9.5 PES 11.8 PES 17.0 Twist packages Material PA PES CV / AR Traverse kg 13.0 kg 14.5 kg Diameter mm 350 The weights are only approximate values, i.e. they may vary with the tube size and package density PA = polyamide, PES = polyester, AR = aramid, CV = rayon, PEN = polyethylene naphthalate CableCorder, Gauge 450 Number of spindles Machine length mm Number of spindles Machine length mm CableCorder, Gauge 500 Number of spindles Machine length mm Number of spindles Machine length mm Machine lengths without dimensions of cooling units Machine lengths with suction duct upwards: dimensions +700 mm per suction tower With package slide option +400 mm CABLECORDER CABLECORDER 15

16 CableCorder Machine dimensions L 1420 gauges 450 and gauge gauge gauge gauge gauge 500 General Research and development never stand still. Therefore, one or the other information about Allma products in this brochure might be outdated by technical progress. All illustrations are chosen from an informative point of view and may show additional devices which do not pertain to the standard machine version. The actual design of the machine is determined by the technical data in our quotation and order confirmation. 16 CABLECORDER CABLECORDER

17 CableCorder Technical and textile data CableCorder Gauge 450 Gauge 500 Gauge 670 Spindle sizes mm Ø/traverse *205/10, 230/10, 230/12, 230/10, 230/12, 250/10, **300/10, **300/12, 250/10, 250/12 (205/12 please consult us) 250/12, 290/10, 290/12 **330/10, **330/12 Number of spindles max Spindle speed rpm max spindle 205, 230, 250 and spindle 290, 300 and spindle 330 Range of twists tpm Direction of twist S or Z Delivery speed m/min or *** in the combi version Materials PA, PES, AR, CV, (PES-HMLS, AR and CV with additional device) Range of counts dtex x 1, x 2, x (please consult us for further yarn counts) Additional devices: Power line filter, interface for production data acquisition, HiLo creel, remote diagnostics, air/water or air/refrigerant heat exchanger, noise abatement, suction upwards or downwards, thread reserve, tension meter, stroboscope, splicer, equipment for processing rayon and aramid, two-for-one package (combi version), CordGuard, clutchable capstan, UPS, assembling device * = not available in the combined version, ** = only available as two-for-one spindle *** = in the combined version the delivery speed depends upon the number of spindles Feed packages Ø 205 mm Ø 230 mm Ø 250 mm Ø 290 mm Ø 300 mm Ø 330 mm kg kg kg kg kg kg Traverse 10 PA 5.0 PA 7.0 PA 8.5 PA 12.2 PA 13.1 PA 16.3 PES 6.0 PES 8.0 PES 9.8 PES 14.1 PES 15.2 PES 18.9 CV 6.2 CV 8.5 CV 10.4 CV 14.7 CV 16.0 CV 19.9 AR 6.2 AR 8.5 AR 10.4 AR 14.7 AR 16.0 AR 19.9 Traverse 12 PA 8.2 PA 10.2 PA 14.5 PA 15.7 PA 19.5 PES 9.5 PES 11.8 PES 17.0 PES 18.2 PES 22.6 Twist packages Material PA PES CV / AR Single yarn Traverse kg 13.0 kg 14.5 kg 17.5 kg Diameter mm 350 The weights are only approximate values, i.e. they may vary with the tube size and package density PA = polyamide, PES = polyester, AR = aramid, CV = rayon, PEN = polyethylene naphthalate CableCorder, gauge 450 Number of spindles Machine length mm Number of spindles Machine length mm CableCorder, gauge 500 Number of spindles Machine length mm Number of spindles Machine length mm CableCorder, gauge 670 Number of spindles Machine length mm Number of spindles Machine length mm Machine lengths without dimensions of cooling units Machine lengths with suction duct upwards: dimensions +700 mm per suction tower With package slide option +400 mm CABLECORDER CABLECORDER 17

18 Fields of application New markets, new opportunities and new products New ideas, product enhancements and interdisciplinary approaches are the driving forces behind innovations in the market. With our CableCorder and CableCorder you are optimally positioned for meeting the challenges of the market. 18 CABLECORDER CABLECORDER

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20 Saurer Technologies GmbH & Co. KG Twisting Solutions Main location: Weeserweg Krefeld Deutschland T F sales.volkmann@saurer.com Subject to alterations Twisting Solutions Further location: Leonhardstrasse Kempten Deutschland T F sales.allma@saurer.com Saurer Hong Kong Machinery Co. Ltd. Room , 28/f, The Center 99 Queen s Road Central Central Hong Kong T F jackson.ye@saurer.com Saurer (Jiangsu) Textile Machinery Co., Ltd. Shanghai Branch Company 36F, Tower B, The HQ, 100 Zunyi Road Shanghai China T F TWI.SH.CN@saurer.com Saurer (Jiangsu) Textile Machinery Co., Ltd. No.9, Chang Yang Street Suzhou Industrial Park, Jiangsu Province China T F info.twi.cn@saurer.com Saurer Inc South Boulevard Charlotte, NC USA T F Twisting.USA@saurer.com