At ITMA Asia + CITME 2025, Barmag presented the completely redesigned POY 2.0 spinning concept, intended to take the production of partially oriented yarn to a higher technical and economic level. The new solution, shown for the first time to a selected group of specialists, attracted strong interest from the market, and several yarn producers from different regions of the world expressed their willingness to install pilot lines already at the premiere stage. A key objective in developing the new concept was a comprehensive analysis of the entire process chain, from spinning to winding, and on this basis the optimisation of core components, reduction of energy consumption and simplification of line operation.
Barmag engineers focused on modernising critical elements of the process line, such as the DIO spin pack, the EvoQuench radial quenching unit and the WINGS POY winder, as well as on integrating the system with a digital process monitoring platform. The result is a solution that, according to the manufacturer, is intended to provide more uniform filament quality, reduced consumption of consumables, shorter changeover times and a reduction in production waste. In addition, partial automation is designed to support spinning mills under conditions of an increasing shortage of skilled personnel and growing requirements for production stability and repeatability.
DIO spin pack: more compact and process-optimised
The new generation of the DIO spin pack has been redesigned with regard to the rheological properties of the molten polymer, which is expected to result in even more homogeneous filament quality across the yarn cross-section. The modified internal geometry is intended to promote a uniform distribution of pressure and flow, which in practice limits fluctuations in fibre parameters.
An important change is the more compact design of the pack. According to the manufacturer, it enables a reduction in filter sand consumption of around one third and a reduction in the component weight by more than 30 percent. Lower demand for filtration media means reduced consumption of consumables and potentially less frequent replacements, which can affect maintenance costs and line availability. The reduced weight of the pack also facilitates handling during service work and changeovers.
The spinning beam also benefits from the changes. The modified design reduces the surface area that must be maintained within the required temperature range, which, according to Barmag, allows energy savings of up to 10 percent. Lower thermal energy demand in the spinning zone is important in the context of rising media costs and requirements for energy efficiency of installations.
EvoQuench 2.0: more stable cooling and shorter changeovers
The EvoQuench radial quenching unit remains a central element of the process, responsible for uniform cooling of the filaments immediately after they exit the spinneret. In the new EvoQuench 2.0 version, design measures have been implemented to facilitate adjustment of the convergence length, i.e. the section where the yarn is guided and cooled before further processing.
The manufacturer emphasises that, thanks to design changes, access to control elements has been improved, enabling operators to adapt settings more quickly to the requirements of individual products. Easier operation translates into shorter configuration times when changing the product range and into a reduction in the amount of material rejected during process stabilisation. As a result, EvoQuench 2.0 is intended to support both higher cooling process stability and more efficient use of raw material.
Wings POY 2.0 winder: automatic string-up and waste reduction
The central component of the new spinning line is the Wings POY 2.0 winder. For the first time, it incorporates an automatic string-up function, which the market has been expecting for some time. Automation of this step is intended to keep string-up times consistently short, which in the long term translates into reduced production waste.
Automatic string-up also reduces the need for personnel at the take-up level. In an environment of increasing shortage of qualified staff, this is an important factor for many spinning mills planning to modernise their machinery or expand capacity.
The new active quick returns enable faster adjustment of product-specific parameters, which is particularly important for frequent product changes and the manufacture of demanding yarn qualities. These solutions are also intended to improve package build quality by reducing the risk of overthrown yarn ends.
Additional shielding of the chuck and packages is designed to permanently prevent the formation of fluffs that could disturb yarn running. Stabilising the yarn path supports trouble-free operation and reduces the risk of unplanned downtime. The new yarn end fixation system has been designed so that loose yarn ends do not appear during handling or transport, which increases the reliability of the entire process.
Eliminating loose ends is particularly important where subsequent stages are automated and based on sensors. Incorrect signals in automated logistics processes resulting from uncontrolled yarn ends can lead to unplanned downtime, which the new solution is intended to help avoid. The optimised XPT housing with a larger rotor stroke increases the permissible package parking time, providing greater flexibility during the doffing process. As a result, the entire system is expected to operate more stably and with higher productivity.
Digital integration with the atmos.io platform
The new POY 2.0 spinning concept has been fully integrated into the atmos.io digital system environment. The implemented solutions enable the individual process stages, from the incoming polymer to the finished yarn, to be linked into a single coherent monitoring and data analysis system.
Various applications available within the atmos.io platform provide operators with a complete view of the production process. Quality parameters, among others, are monitored, allowing operating staff to react quickly in the event of deviations from target values. Continuous control and networked data exchange are intended to lead to reduced waste volumes, improved final product quality and better margins through more stable and predictable production.
The manufacturer stresses that combining mechanical solutions, such as the modernised DIO spin pack, the EvoQuench 2.0 cooling unit and the Wings POY 2.0 winder, with digital systems is expected to enable further optimisation of POY yarn manufacturing processes. Integration within the atmos.io digital environment provides a basis for better use of process data, which can support maintenance planning, root cause analysis of disturbances and continuous improvement of production parameters.
Barmag POY 2.0 spinning concept with Wings POY 2.0 winder and new generation DIO spin pack
