BEN- SINGLESIZE

Single-end sizing
of filaments
every beam alike
Single-end sizing is certainly the gentlest way to size filament yarns.
All the same there are some points to be noted, that are absolutely essential
if high quality as well as high productivity are to be achieved.

What is expected from a modern

single-end sizing machine

Thread tension tensions from the individual sizing beams Drying

Perfect control of the thread tension in
all operating states (normal running,
slowing down and accelerating) is cru-
cial when sizing filament yarns, because
differences in thread tension are imme-
diately reflected in the cloth quality.
Especially in single-end sizing, the thread
must be absolutely equal, because
mistakes can no longer be corrected in
subsequent assembling.
Filament warps must not be overdried.
Such warps will at best produce seconds,
if not reject cloth, because dye uptake
is altered. Overdrying happens mainly at
reduced speed or when stopped.

2
Size pick-up
Uniform sizing over the entire width and
length of the warp is the basic require-
ment for sizing. The pick-up level should
be optimal, without over- or undersizing.
Size consumption must be kept as low
as possible, not just to save costs, but
to reduce environmental pollution when
washing-out the finished cloth as well.

Attendance-friendly
Good results in sizing are obtained not
only through control engineering, but
also by simple and easily understand-
able plant attendance. Deviations
or faults must be detected at once.

Drive engineering, process regulation

On sizing machines, individual motor
drives are replacing the previously
familiar longitudinal shafts and their
associated mechanical variable-speed
gears. PLC controls are replacing
hardware controllers. Maintenance and
repairs are simplified.

3
There are different plant configurations available for meeting the different
process requirements in single-end sizing.

Tailor made solutions

for different requirements

Single-end sizing from back beam

This has the advantage that end breaks
due to poor yarn quality have already
occurred in beaming and have been
cleared. Fluff also is removed in warping.

Single-end sizing from package creel

Particularly economical, as beaming is
omitted. However the process calls for
good yarn and package quality. Too
many end breaks in sizing will impair the
warp quality and compensate the prod-
uctivity gain.

Single-end sizing without

cylinder dryer
Used for special purposes, such as siz-
ing fine glass yarns. The sizing machine
is equipped with an efficient air dryer,
allowing the cylinder dryer to be elimi-
nated.

4
5
Zone 1: Warp let-off
Correct draw-off tension is a major factor in sizing, because mistakes can
no longer be corrected in the zones following.
Proven package creel
Various creels are available for a variety
of needs. Swivelling frame creels are
employed mainly, loaded from outside
and drawn off from inside. And finally
there are truck creels and standard
creels.
Perfectly controlled thread tension
right from the start
Uniform thread tension with
ISOTENS
Constant thread tension, smooth thread
run and simple attendance and main-
tenance are the outstanding characteris-
tics of this thread tensioner with two
pairs of disks. The first pair smoothens
the thread run. The tension adjustment
at the second pair is preselected cen-
trally and is motorized.
The motor-driven disks prevent dust
build-up and extend the service life.
6
FILGARD for sure monitoring
The FILGARD thread detector responds
very quickly. Via a contactless circuit
the end break is detected and an elec-
trical signal given. The function is not
impaired by fouling and corrosion.
Detailed data on creels, thread tension-
ers and thread detectors may be
obtained from the special BEN-CREEL
prospectus.
No-displacement measuring roller
for measuring tension
Between the creel and the size box
an electronic measuring roller can be
employed to detect the actual thread
tension. When the tension deviates from
its setpoint it is corrected automatically
by powered adjustment on the creel.
Motorized beam unwinder wiht thread run to the
size box

Your profit from these advantages

Package creel
• Proven Benninger creels

Powered brakes on beam let-off • No-displacement measuring roller for

This simplified version incorporates all constant, controlled thread tension

functions for simple handling. The
device for lifting beams in and out is Beam unwinder
powered, as are also the beam sup- • Highest-precision draw-off tension

ports. The thread tension is measured from back beam, controlled via
with a pneumatically loaded pendulum pendulum roller
roller and regulated automatically. • Simple handling thanks to Handymat

and motor-assisted functions

• Constant thread tension even at

higher speeds

7
Zone 2: Sizing
In the size box uniform sizing over the entire warp width and over the
entire length is achieved.
Uniform sizing over the warp length
The liquor uptake, i.e. the degree of siz-
ing, depends mainly on the speed and
the squeeze pressure. Benninger has
therefore developed a special program,
enabling squeeze pressure curves to
be fixed and stored individually.
Uniform sizing widthwise
Like dyeing, sizing too calls for abso-
lutely uniform squeeze pressure distribu-
tion over the entire warp width. Only
then is uniform sizing possible from the
left side through the middle and up to
the right side.
This first of all requires a special squeeze
roller with mathematically exactly defined
flexing characteristic.
Secondly it is essential that the pneu-
matic squeeze pressure is applied
using special bellows cylinders. Only
Proper sizing at all times
these can assure hysteresis-free squeeze
pressure application, because the pres-
sure is brought to bear without pistons
and their seals. The frequent speed
changes on the sizing machine, dictated
by the residual moisture control, neces-
sitate continuous adaptation of the
squeeze pressure. These small correc-
tions can only be made satisfactorily by
a system without friction losses.
8
Circulation system
Speeds up to 500 m/min are run in
single-end sizing. To avoid troublesome
foaming, the immersion roller does not
run in the liquor but is merely set to the
squeeze roller. Between the two rollers
a liquor bath results; it is here that the
actual sizing takes place. The liquor is
supplied through a duct above the
squeeze roller.
The outflowing size passes through wire
filters and a mat into a separate tank,
freeing it of coarse dirt and spinning oils.
An additional fine filter removes small
dirt particles from the size.
The temperature is measured inside
the circulation system and controlled
via indirect steam heating.
Unlike conventional piston cylinders, special
rubber bellows cylinders enable frictionless pressure
application and can bring the required squeeze
pressures to bear without hysteresis.
 Precise measurement of
size liquor usage
The liquor level in the size box is meas-
ured continuously by pressure sensors.
This is accurate, insensitive to size
contamination and maintenance-free. It
ensures that the size box is kept filled
and measures the size liquor consump-
tion. From this the actual size pick-up
is calculated.
The sophisticated circulation system ensures
a homogeneous size liquor.
9
Free access and maintenance without
problems
The size box is freely accessible from
all sides. Safety devices to EC stand-
ards protect against dangers while the
machine is running. The squeeze rollers
can be exchanged quickly.
HANDYMAT for simple attendance
The portable HANDYMAT enables a
single operator to clear an end break.
He can start or stop the machine at
the same time.
Your profit from these advantages
• Constant sizing over the warp width
and batch length
• Circulation with clean liquor free of
foam
• Optimized minimal size pick-up
• Attendance with proven HANDYMAT
without additional keys
• Safety devices to EC standards
• Precise maintenance-free size
consumption measurement
Zone 3: Drying
Benninger’s many years of experience are reflected particularly in
its air dryer technology, which embodies the know-how gathered
from engineering major dryers for tyrecord plants.
Dependable thread monitoring
By means of driven and cooled wet split
rods the thread sheet may be split into
as many as 5 layers after the size box.
End breaks are detected quickly and
dependably by laser light barriers.
Short stopping time ensures
no lost ends
The modern drive control enables the
machine to be brought to a stop from
400 m/min in less than 4 seconds,
so that broken ends can still be mended
within the sizing plant. This also pre-
vents further breaks in the comb.
Laminar air currents in the
hot air dryer
All Benninger air dryers feature abso-
lutely laminar air flow. Even on extremely
long dryers the air is led over the thread
sheet free of turbulence. This allows the
thread tension in the dryer to be reduced
without cording. Stretching losses can
be largely avoided in this way.
A well-thought-out air ducting system
assures uniform air distribution over the
entire working width.
Efficient dryer systems
No overdrying
When the machine stops, the upper part
of the dryer is raised automatically and
the heating turned off if necessary.
This prevents the warp being overdried,
and also facilitates and speeds up deal-
ing with any end break.
Optimal insulation
Insulation 120 mm thick prevents energy
losses. Together with the rear-ventilated
sides it ensures that temperature of the
outer surfaces does not exceed 30 °C.
Heating medium to choice
Standard air heating is by a steam-
heated pipe bank. An additional electri-
cally heated bank ensures constant
temperatures up to 160 °C with varying
steam pressure.
For higher dryer temperatures the pipe
bank can be heated with oil. Another
alternative – the most economical one –
is heating with natural gas.
10
Controlled air humidity
The drying capacity depends essentially
on the air humidity in the dryer. If the air
is too moist, performance will fall off. If
it is too dry, the dryer will draw in too
much fresh air and the energy consump-
tion will go up. The humidity can be
regulated to an optimal level by automa-
tic hygrometers in the air stream and a
power-controlled exhaust air valve. Low
energy usage and constant dryer per-
formance at calculable machine speed
are the gratifying results.
Your profit from these advantages
• Absolutely uniform drying over the
entire warp width and length
• No cording even with lowest thread
tensions
• Heating medium to choice
• No overdrying
• Attendance made easy
• Controlled air humidity for low
energy usage
 Two-layer air dryer for uniform drying
and high performance.

Single-layer air dryer

Depending on the process temperature
desired, the air can be led either with
the running direction of the thread sheet
or counter to this. The air is delivered
by two fans through the heating bank.
Guide plates after this ensure laminar
air flow and air temperature without
streaks. This up-to-date technology guar-
antees a maximum temperature differ-
ence of +/–2° over the entire width of
the dryer.

Two-layer air dryer

The two-layer dryer consists in essence
of two superposed air dryers. The hot
air is then led from above and below
parallel past the thread sheet, ensuring
uniform drying. With gas burners the
capacity of the air dryer can be
increased up to 4 times compared with
the standard air dryer. It is then possible
for technical and economic reasons to
dispense with cylinder dryers altogether.
With regard to perfect air control and
temperature control accuracy, the two-
layer air dryer offers the same precision
as the single-layer dryer.

11
Often temperatures below 100 °C must be used in the cylinder dryer.
Overdrying must be avoided. Even at high speeds up to 500 m/min the
drive must function reliably without needing attention.

Optimized cylinder dryer

Precise temperature control in the Maintenance-free drive

cylinder dryer
An ingenious condensate extraction and
positioning of the temperature sensors
enables temperatures below 100 °C to
be regulated without problems even in
the cylinder dryer. This heating also is
turned off when the machine stops. The
turn-off timing can be preselected to
prevent overdrying the warp.
The cylinders are driven by especially
quiet-running toothed belts, which require
very little maintenance compared with
roller chains. As the toothed belts are
not greased, no grease can be splashed
onto the warp.

Your profit from these advantages

• Precise temperature control even
for temperatures below 100 °C
• Maintenance-free drive without
greasing
• Preselectable turn-off timing rules
out overdrying

12
Zone 4: Dryer exit and cooling zone
Precise measuring of the residual moisture at the dryer exit is important
for fault free beaming and high production. In the efficient cooling zone
the warp must be cooled down until no gumming can occur on the
weaver’s beam.

Precise residual moisture control

Measuring residual moisture

At the dryer exit the residual moisture is
measured accurately and regulated via
the machine speed. Even values down
to 0.3% can be measured exactly, and
this with yarns of only 5% size pick-up.
On the machine’s PC the material to be
sized may be entered. The right residual
moisture curve is then selected auto-
matically and the effective moisture is
indicated.

Programmable waxing device

To obtain uniform waxing, the speed of
the wax roll is adjusted proportional to
the machine speed.

Cooling
The cooling device serves to cool down
the thread sheet so that this is wound
onto the beam not too hot. It operates
by blowing cooling air against the
thread run.
Benninger supplies a central cooling unit
for air conditioning in the main electrics
cabinet, as well as supplying cold water
to the wet split rods and the cooling
device. The energy demand is lowered
significantly by this system.
Your profit from these advantages
• Precise residual moisture measur-
ing down to 0.3%
• Size pick-up down to 5% measured
with extreme accuracy
• Simply programmable waxing
device
• Economical cooling device

13
The beamer features ergonomic attendance and an up-to-date
drive concept.

Simple handling when beaming

Simple drawing forward

by clamp roll
To draw the thread sheet forward when
changing beams, the clamp roll is pressed
against the deflecting roller. Enough
yarn is then drawn forward automatically
to enable satisfactory winding onto the
beam. No manual interventions are
needed.

Low-maintenance drive
The back beam drive is built straight
onto the beam support. The three-phase
asynchronous drive ensures complience
with to the programmed values. It is
energy-saving and maintenance-free.

Comb traversing
The comb traverse is steplessly adjust-
able to assure uniform beam winding.
The traversing speed may be selected
optionally, proportional either to the
machine speed or the beam rpm. The
comb adjustment is power-assisted and
requires no effort.

14
Ergonomic attendance
with HANDYMAT
With the HANDYMAT portable attend-
ance terminal, all jobs are performed
conveniently wherever there’s something
to be done. Whether lifting the beam in
or out, adjusting the beam or taping-off:
the operator always has all the controls
in his hand. All operations are power-
assisted and require only minimal exer- In the course of development importance was
tions. attached to an overall height as low as possible to
Needless to say, the beamer complies facilitate access to the comb
with the latest European safety regula-
tions.

Your profit from these advantages

• Even beam surface

• Constant thread tension and beam
hardness
• Effortless attendance with the
portable HANDYMAT
• Safety to EC standards
• Dynamic maintenance-free drive
system
• Precision comb traverse

15
BEN-SINGLESIZE embodies a process control system and regulation that
guarantee not only maintenance of the programmed parameters but also
absolute reproducibility of production in the long term. They also facilitate
attendance and programming of the instalation and provide a better
overview with clear graphic displays.

Quality by precise
thread tension

Tension control tailored to your needs Stretch-sizing

On the back beam creel the entire thread
tension can be detected with a measur-
ing roller and regulated via the power-
adjusted thread tensioners.
On the powered unwinder the tension is
regulated via a pneumatically loaded
pendulum roller. Constant tension is
maintained even with back beams not
running true.
Within the sizing machine, pneumatically
loaded pendulum rollers and measuring
rollers are employed. Dyeing differences
due to varying thread tensions in sizing
can be eliminated with this precise
control.
Precision measuring and drive allow
socalled stretch-sizing on this machine.
The warp is then stretched by the nec-
essary amount in the wet state between
the size box and the cylinder dryer.
High-dynamic maintenance-free drive
Three-phase asynchronous motors are
used exclusively on BEN-SINGLESIZE.
Inaccurate longitudinal shafts with vari-
able gears, demanding much mainte-
nance, are eliminated. Speed regulation
is by ultrafast PROFIBUS, linking the
motors with the PLC.

M = Motors

16

Attendance with HANDYMAT
Throughout the machine pushbuttons
are kept to the minimum. Attendance is
carried out with the HANDYMAT, on which
all functions of the particular equipment
are grouped together.
• Attendance is performed where the
action is – important when lifting beams
in and out, adjusting the comb, etc.
• End breaks are cleared by a single
person, who can start or stop the
machine at the same time.
• The number of control keys is reduced,
and with it the potential sources of
error.
• Up-to-the-minute statuses are indicated
in the small display.
Attendance and monitoring
overview
Transparent and reproducible
processes
Attendance at the PC of BEN-SINGLE-
SIZE is guided by simple, easily under-
stood all-graphic displays. Handling is
made still simpler and quicker by the
maintance-free touch screen. The set-
points and actual values are shown
on the particular sub-unit, making mis-
understandings almost impossible.
Double process security
The system has integrated tolerance
monitoring, enabling the operator to de-
termine the tolerances for any setpoint.
If one is exceeded, speed is reduced
or the machine stopped. Constant warp
quality is guaran-
teed.
17
Reproducible production
All installation parameters can be stored
under a recipe name, for recall or print-
out any time. This facilitates entering
a new lot and guarantees reproducibility.
For process monitoring, a log may be
printed out for each beam.
Via a password system with 5 levels,
the various operators are given more or
less freedom to intervene.
Your profit from these advantages
• Absolutely constant thread tensions
• Maintenance-free asynchronous
drives
• Reproducible and controlled quality
• Attendance simplified by
HANDYMAT
• Fault diagnosis on PC direct with
help masks
 State-of-the-art control

Attendance-friendly control
Host computer
The installation is controlled by a
SIEMENS PLC assisted by PROFIBUS.
The central computer is accommodated Ethernet
in the air-conditioned electrics cabinet.
The input and output PCBs are located
Machine PC PLC
at the particular sub-units and are linked
by signal cable to the PLC. The bus
Profibus
modules (input and output PCBs) toler-
ate thermal stress much better than a
PLC and need no air conditioning. AC-drives
Handymat
I/O-moduls
Analysis with long-term archive
This option enables all production
parameters to be stored for 3 months.
The desired production data may be
checked afterwards at any time. The
data may be down-loaded via a network
to a higher-level system, making them
available for an unlimited period.

Remote diagnosis by TELESERVICE

Inside the electrical cabinet is a modem,
with which your installation can be con-
nected to the appropriate Benninger
service station. The service technician
can query the state of the installation
and make a diagnosis. That way any
repairs can be done faster and at lower
cost.
Your profit from these advantages
• Less cabling and hence less trouble-
proneness
• Speedier repairs at less cost
• Process data stored for subsequent
checking and analysis

18
The range of cooking and mixing plants extends from the ordinary,
manually charged cooker to the automatic mixing plant with automatic
charging.
Automatic mixing
When using liquid basic ingredients, with
this plant water is mixed into the stock
size to reach the required concentration.
Since these sizes are applied at tempera-
tures around 25–35 °C, no additional
steam heating is needed. If necessary
the basic ingredients are mixed with hot
Reproducible size preparation
water. Mixing and filling the size box are
fully automatic. The size parameters are
entered on the machine PC or recalled
from the recipe memory.
19
Manual cooking
Standard cookers and storage tanks are
available up to about 1200 litres capac-
ity. Control and attendance may be
effected optionally either from a console
at the cooker or on the PC of the sizing
machine. Of course the cooking plant
may also be linked to the PROFIBUS
and the associated diagnosis system.
storage mixing
tank device
stock
tank
Automatic mixing
Your profit from these advantages
• Reproducible size recipes to high
quality standard
• Fully automatic praparation
and supply
• Personnel costs cut
• Low investment costs
From the Warping Sizing/Dyeing (Weaving) Desizing Pretreatment Dyeing/Post-Treatment/ ... to the
bobbin… • Direct beaming • Sizing Benninger- • Direct desizing • Scouring & bleaching Impregnation finished
• Sectional warping • Indigo-dyeing Partner without batching in one passage • Pad-dry thermosol fabric
• Autom. sectional • Cold sizing • Washing • Mercerizing • Pad-steam
warping • Washing • Washing
• Drying • After print washing
• Drying
• Dip- & hot stretch line

Your partner
for weaving preparation

From the package to the finished cloth,
Benninger has a wide and varied range
of equipment for all processes before
and after weaving.
Benninger weaving preparation ma-
chinery guarantees outstanding warp
quality and production always optimal
and reproducible. From the creel
through direct beaming or section
warping, sizing or indigo dyeing, irre-
proachable running performance in
weaving is always the first objective for
high efficiencies and good cloth quality.
The development, production and
assembly of all Benninger equipment is
accomplished exclusively in our own
works in Switzerland, Germany and Italy.
This ensures that manufacturing stand-
ards are monitored continuously and
optimized. New demands from cus-
tomers are continually accommodated
in development and production.
Instruction, know-how transfer
and service
The ever-rising quality and productivity
demands in modern textile operations
call for trained personnel to operate and
maintain the machinery and carry out
the process technology that determines
the quality. Instruction courses with
Benninger or at the customers’ plant
impart the necessary basics and prac-
tical experience.
Affiliate companies and offices of the
Benninger Group maintain and operate
a close network of service points and
spare parts depots.

Benninger AG
CH-9240 Uzwil/Switzerland
Phone +41 71 955 85 85
Fax +41 71 955 87 47
E-Mail: benswiss@benningergroup.com
Internet: www.benningergroup.com

Benninger Zell GmbH

D-79665 Zell
Phone +49 7625 131 0
Fax +49 7625 131 298
E-Mail: bengermany@benningergroup.com

The data and illustrations in the document correspond

to the technical level at the time of printing and do not
constitute a part of any offer. The right to make alter-
nations is reserved.

© Copyright Benninger AG
682-e DF – May 1999, Printed in Switzerland