A Raschel machine from and for China

KARL MAYER’s new RJ 5/1 offers improved price-performance ratio, and attracts a lot of attention in China

With its new machine KARL MAYER brings fresh impetus to the market of patterned Raschel fabrics in China. The newcomer with the designation RJ 5/1 was launched at an in-house show held at KARL MAYER (CHINA) during ShanghaiTex, 2019, where it was a real crowd puller.

Especially due to its excellent value for money, this highly efficient model catches the manufacturers’ attention. Offering attractive acquisition costs, the RJ 5/1 is more productive than comparable competitor products. Moreover, the machine has a highly stable and very precise machine run. The textiles produced on this machine impress by their outstanding quality. Featuring trendy designs and a style that minimizes making-up, the possible products of the RJ 5/1 are tailored to the needs of the Chinese market.

A machine for the lingerie and clothing market in China

With this machine from local production – manufacturing site is KARL MAYER (CHINA) – the Product Manager, Kriss Wang, wants to address the domestic customers belonging to the commodity market. He sees great potential for modernization projects in particular. “We submit a cost-efficient offer especially to those RSJ users, who want to modernize their factories”, explains this textile expert. The patterning portfolio of the RJ 5/1 machine includes traditional articles from the RSJ sector such as charmeuse, made with three guide bars, as well as elastic and rigid Power Net constructions. With its enormous design possibilities, this new development encourages especially the current seamless trend. Back and front parts with opaque areas, lace-like tapes and contourings for making-up are made in one piece, directly during fabric production. Leg openings and arm holes of the free-cut article do not have to be seamed. Only very few seams are required for closing the styles during the final processing. One example was shown during the in-house show at KARL MAYER (CHINA). In the course of the machine presentation, a 130″ model produced a swimwear fabric in a gauge of E 32, with a lot of chic and easy make-up. Even the KARL MAYER lettering was seamlessly integrated into the eye-catching element ensemble.

Availability from 1st quarter 2020

The RJ 5/1 is available since China New Year, in the gauges of E 32 and E 28 and in a working width of 130″.

KARL MAYER – A new, sure-fire success is in the starting blocks

Successful launch of the RDJ 6/1 EN, with its high cost:benefit ratio, for the shoe fabric sector

KARL MAYER has expanded its range of machines with piezo jacquard technology for producing stylish shoe fabrics, and the new RDJ 6/1 EN has now been incorporated into the series comprising the RDPJ 7/1 EL and RDJ 5/1 machines. This new machine has a better price, and operates faster than the higher-bar version. However, there is very little difference in terms of the design potential. Almost 90 % of the jacquard shoe fabrics currently produced can be manufactured on the RDJ 6/1 EN. The configuration of this new machine makes it ideal for producing engineered spacer textiles. Compared to the RDJ 5/1, the RDJ 6/1 EN has one extra guide bar, EN drive and a wellthought- out yarn feed system to the jacquard bars, and offers extended design possibilities, a higher product quality, and easy pattern change. The cost is still competitive.

A high-performance machine for producing shoe fabrics

The RDJ 6/1 EN is available in the gauges of E 22 and E 24, and has a working width of 138″. The distance between the knock-over comb bars can be adjusted continuously from 2 mm to 8 mm. Customers can now buy a flexible production machine with five guide bars, one split jacquard bar, whose split bars can operate in a counter lapping operating mode, and an EN pattern drive. It can also produce an extensive range of fabrics. Dense structures can be worked, as well as a wide range of patterns with holes, which can be of any size and placed in any location. The result is attractive shoe fabrics with a specific breathability. If the split jacquard bars are moved in a counter lapping operating mode, the contours of the openings are exceptionally clear. In this case, the yarn is fed from two sectional warp beams. This facilitates yarn drawing-in and doubles the yarn running times – with a positive effect on the productivity The EN drive makes a further contribution to increasing the efficiency. The seven electronic guide bar drives enable the patterns to be changed very easily and flexibly, and the costs of buying, storing and changing the pattern discs are eliminated. Like all KARL MAYER’s machines, the RDJ 6/1 EN can also be operated very easily. A new feature compared to the RDJ 5/1 is that the machine and knitting elements are equipped with LED lighting as standard. The increased visibility simplifies handling even more, especially when drawing-in the yarns. This new doublebar raschel machine is completely compatible with the RDJ 5/1 and the RD 7/2-12 EN as far as the knitting elements are concerned. This reduces the storage requirements for spare parts.

Successful market launch

The RDJ 6/1 EN was presented to a wide audience for the first time at the in-house show held at KARL MAYER (CHINA) during ShanghaiTex, which took place from 25 to 28 November 2019. The visitors asked many questions about the new machine. Yuji Yamamoto, the Product Manager at NIPPON MAYER, is preparing to have many discussions on various projects in the next few months. Mass production was scheduled to start in September 2019, and the first machines have already been sold.

KARL MAYER – Constant control of yarn tension

The new MULTIGUARD yarn monitor gives advance warning of a yarn breakage

Modern sensor technology and data processing systems can be used to control all the important processing parameters and also to implement a wide range of optimisation measures. The production sequences can be optimised, as well as entire value-added chains. The efficient monitoring of yarn tension and feed during warp preparation can increase weaving efficiency by up to 5 %. The new MULTIGUARD stop motion from KARL MAYER can make an important contribution here. This innovative system gives a warning in the event of yarn breakages or tension peaks, and generates parameters that can be used for internal production data management as well as external quality assurances within the framework of a quality management system.

All the yarn tension levels at a glance

MULTIGUARD continuously determines the tension values of each individual yarn at the exit of the creel and transmits the data to a computer for comparison with the target values. This generates a clear status report. The coloured indicators show the customer immediately which creel position lies within the tolerance, warning or stop ranges. This enables him to intervene quickly in the warping process if there are any deviations from the target values. The specific, measured tension values are displayed in a compact diagram. They can be used for internal analyses and for quality management of the warping process. KARL MAYER has also developed the PROACTIVE-Warping three-level, modular recording system, whereby each level contains more information. Module 1 manages all the basic data supplied by sensors on the warping machine relating to the warping or beaming quality. For example, the data relates to the exact positioning of the bands in relation to the drum axis. Level 2 complements these values with optical analyses from an integrated camera on the machine, whereby the focus is on the width, position and parallel arrangement of the bands. In module 3, the data is also transferred to the quality record from the creel monitoring system, i.e. the individual yarn tension values from the MULTIGUARD system.

A good start on the market

MULTIGUARD was launched as a prototype for the first time at ITMA 2019, and this innovative system generated a huge level of interest. “The possibility of detecting critical deviations in yarn tension levels early on, and to intervene in order to adjust them was well received by our customers,” says Martin Fuhr, the Head of Development in KARL MAYER’s Warp Preparation Business Unit. A Belgian customer has already ordered the new yarn monitoring system. Further promising projects are currently being negotiated. MULTIGUARD is suitable for every type of creel. It is integrated into the machine’s software and monitor on new machines.

KARL MAYER – A bralette full of promise

A new bra concept developed by Lisa Bahr makes use of the possibilities offered by the JACQUARDTRONIC® LACE

Modern technology and fresh, new ideas produce stylish designs and offer production advantages. Lisa Bahr has shown how this can be done in her work for her master’s degree. This student of Textile Products/ Textiles at the Hochschule Niederrhein (University of Applied Sciences, Niederrhein) has developed a completely new bra design and associated bralette using the features offered by the JACQUARDTRONIC® LACE machine – based on the motto, “smart and speedy”. This innovative item of lingerie is made from just two lace pieces with two seams joining them together to produce the final garment – and moulding, pads or underwiring are no longer required. The shape of the cup is built into the textile itself. “I wanted to give the bust the best possible shape, so I focused on the concept of two-way elasticity. Conventional lingerie lace is only stretch in one direction. When used in a design that requires very little making-up, the circular shapes are flattened out. The effect is the same as that of a sports bra or minimiser.” To put her idea into practice, this young designer relied on the expertise and knowhow of KARL MAYER, and on the performance of a high-bar JACQUARDTRONIC® LACE machine. As with normal lingerie fabrics, she processed all-over elastane on the high-performance lace raschel machine, but combined the uncovered yarn with a covered yarn as the pattern yarn. “The stretch, core-spun yarn can be processed better in the pattern guides. It also retains the textile characteristics of the fabric,” explains Lisa Bahr. This student was inspired by the organic shapes of floating bubbles when creating her design, which features circular motifs in a subtle interplay with transparent and opaque effects. The result is a bralette with a seductive look, a comfortable fit with few seams, a short time-to-market, and low production costs. A special little trick was used during production, i.e. the design of the back section of the bralette can also be used to produce the matching briefs.

Toyota and Toyota Industries Jointly Develop New Battery for Hybrid Electric Vehicles

Toyota Motor Corporation
Toyota Industries Corporation

Toyota City, Japan, February 20, 2020―Toyota Motor Corporation (Toyota) and Toyota Industries Corporation (Toyota Industries) announce that they have jointly developed a new battery for hybrid electric vehicles (HEV). The battery has been developed in anticipation of the further development and market introduction of HEVs, forecasted to rapidly expand in the future. Moving forward, the companies will proceed to discuss matters such as target vehicle models as well as battery specifications and performance, prior to equipping Toyota HEVs with the new batteries.

Additionally, in order to meet the demand for increased production of Toyota HEVs, the production of the new batteries is planned to take place at Toyota Industries’ Kyowa Plant (Obu-shi, Aichi Prefecture) and at a site on company property located adjacent to their Higashiura Plant (Higashiura-cho, Chita-gun, Aichi Prefecture). In the future, Toyota Industries will work with Toyota to build and strengthen the supply structure.

Moving forward, Toyota and Toyota Industries will promote the development of technology and products to support the popularization of electrified vehicles as the Toyota Group aims to help reduce CO2 emissions to help curb global climate change.



Toyota Industries Corporation Gains the Highest Rating in Survey by CDP*

~ Chosen as an A-List Company for “Climate Change” for a Second Consecutive Year ~

Toyota Industries Corporation (President: Akira Onishi) was selected for the A-List, for the second year in a row, in the surveys on climate change conducted by CDP. Toyota Industries made the A-List, the highest evaluation, as a company of particular merit in activities that include the reduction of greenhouse gas emissions and measures to alleviate climate change. The ratings were formally announced on January 20 at the CDP 2019 Japan Report Launch.

At the Report Launch, Hiroaki Matsuda, Executive Officer at Toyota Industries, described the company’s aim to contribute to the achievement of CO2 zero emission society by 2050. And he commented we would like to accelerate our environmental conservation efforts, including the development of environmentally friendly technologies, with the keyword of “clean zero emissions” in Toyota Industries’ Vision 2030 (formulated in 2019).

CDP Climate Change
2019 A-List Logo
Toyota Industries’ Executive Officer Hiroaki Matsuda
speaking at the CDP 2019 Japan Report Launch

Toyota Industries Group formulated its “Ideal state in 2050” in March 2016 and, based on this, consolidated its activities for the five years from FY2017 to FY2021 in its “Sixth Environmental Action Plan,” which is currently implemented on group wide basis.

The Group is driving the following initiatives based on the above plan:
1. Reduction of CO2 emissions by 10% by FY2021 compared with FY2006 (Toyota Industries)
2. Reduction of CO2 per unit by 26% by FY2021 compared with FY2006 (Toyota Industries Group)

Toyota Industries is deploying various energy-saving initiatives towards achieving these specific goals throughout Toyota Industries Group. This includes introducing the use of carbon-neutral biogas at its lift truck production plant in Sweden in 2019, in order to attain zero CO2 emissions at all its plants overall. We believe that receiving the highest rating for the second year in a row means that these initiatives have been recognized.

In the future, Toyota Industries Group will continue to tackle climate change as a key issue. Furthermore, the company will contribute to the realization of a sustainable society through global environmental conservation activities.

*CDP is a global not-for-profit charity launched in the U.K. in 2000 that promotes reduction of greenhouse gas emissions, and protection of water resources and forests by companies and governments.
In 2019, CDP conducted surveys and evaluations of major global companies on behalf of 525 institutional investors (total assets under management: 96 trillion U.S. dollars) and 125 companies and organizations (total procurement expenses: 3.6 trillion U.S. dollars).

KARL MAYER – PRODYE-R the evolution in indigo rope dyeing & PRODYE-S advanced technology in indigo slasher dyeing

This indigo rope dyeing machine impresses with an extremely solid physical bond of the indigo dyestuff, homogeneous build-up of ropes as well as excellent washing results and protects the environment by using less chemicals.

KARL MAYER’s future- and customer-oriented indigo dyeing machine is an efficient tool for the production of uniformly dyed indigo warps made at the highest econonomical level and produced with an environmentally conscious process.





El ciclo de vida de una línea BRÜCKNER asciende generalmente a aprox. 20 – 30 años, en excepciones incluso más – se trata entonces verdaderamente de una inversión a largo plazo y orientado hacia el futuro. Durante este tiempo pueden aparecer cambios en las condiciones de producción que reducen la competitividad:

  • Cambian las exigencias respecto a la capacidad de la línea
  • Condiciones cambiadas en el mercado precisan el acabado aun más exacto del tejido
  • Gastos de energía y de producción tienen un efecto creciente al precio del producto final
  • Hay que considerar especificaciones medioambientales

No en todos estos casos es necesario invertir en una línea completamente nueva. La realización de medidas enfocadas de modernización o extensión de líneas BRÜCKNER existentes permiten también una ventaja técnica y tecnológica. Ofrecen no solo una implementación más rápida y menos costosa sino optimizan también claramente el rendimiento.

Les ofrecemos para ello Upgrade-Kits pre-definidos adaptados a ciertos tipos de líneas y que han sido probados ya muchas veces en la práctica. Por supuesto ofrecenmos también la posibilidad de modernizaciones individuales.

Aquí hay un resumen de nuestros Upgrade-Kits:



Su contacto

Kevin Mayer
Head of Modernisations & Upgrade Sales
+49 7152 12-396


RÖKONA – el fabricante totalmente integrado de textiles técnicos altamente especializados confía en la tecnología de BRÜCKNER

Poco después del final de la Segunda Guerra Mundial, Gerhard Rösch fundó la fábrica textil Gerhard Rösch GmbH en Tübingen en 1949 con una sola máquina de tejer. En esa época, la compañía producía principalmente textiles de ropa de noche para damas, así como polos y camisas para hombres. Con la fundación de RÖKONA Textilwerk GmbH & Co. KG en 1963, la empresa de Tübingen se estableció no sólo en la industria del vestido sino también como un innovador productor textil y pronto suministró soluciones textiles técnicas a conocidos fabricantes de automóviles. Hoy en día, RÖKONA desarrolla y produce una amplia gama de textiles sofisticados para todo el sector de la movilidad, así como para aplicaciones industriales, desde la protección de edificios hasta los textiles médicos y la protección contra los cortes para los trabajadores forestales.

La flexibilidad y la alta fiabilidad de los procesos es el requisito previo básico para una producción exitosa y orientada al cliente. Igualmente importante es un parque de máquinas eficiente. Durante más de 40 años RÖKONA ha confiado en las líneas de BRÜCKNER para el acabado de sus textiles de alta calidad. El fabricante alemán de maquinaria textil no sólo suministra líneas a medida para el acabado textil, sino también la tecnología necesaria. En estrecha colaboración con el cliente se desarrolla la solución perfecta para cada aplicación y cada proceso. La exitosa asociación de las dos empresas familiares alemanas ha continuado recientemente con la puesta en marcha de otra línea de rame extra ancha. En cooperación con el equipo de proyecto del cliente, se planificaron diferentes recorridos de tejido dentro de la línea para poder equipar los diferentes tipos de tejido de RÖKONA con la menor tensión posible. Una lavadora de tambor con una almohadilla de impregnación recién desarrollada se instala aguas arriba del marco de la rameta. El exceso de licor residual se elimina en gran medida aquí. En la entrada de la rama, un enderezador con un sistema de accionamiento inteligente asegura un recorrido preciso del tejido sin distorsiones en curva o diagonales. En el interior del secador del marco de la rameta hay una uniformidad de temperatura extremadamente alta en todo el ancho y largo del secador. Esto se debe por un lado a la disposición contraria de las fuentes de calefacción cada 1,5 metros y por otro lado al sofisticado sistema de ventilación de la estructura de rameta BRÜCKNER. Debido a la fijación absolutamente uniforme se garantiza la mayor calidad de tejido posible. La nueva cadena del bastidor del rameador, libre de lubricación, ofrece considerablemente menos mantenimiento y gastos para el cliente. Se consiguen más ahorros de costes mediante la instalación de sensores que minimizan el consumo de energía del proceso y mediante motores de ventiladores optimizados energéticamente. Para el control y la supervisión de la producción, el sistema está conectado al sistema ERP existente mediante una interfaz de datos. Al final del nuevo sistema de 6 compartimentos, el tejido se enrolla en un portamaterias casi sin tensión gracias a un sistema de control por bailarín muy sensible. Esto es extremadamente importante para RÖKONA para lograr un teñido absolutamente parejo y uniforme del textil.

RÖKONA también es muy activa en el campo de la sostenibilidad y la protección del medio ambiente. Junto con todas las ramas existentes, la planta recién entregada también está conectada a un sistema de postcombustión regenerativa, que está integrada en la red de calefacción urbana de la ciudad de Tubinga. El aire caliente de salida de las ramas se limpia primero térmicamente y luego se utiliza para calentar agua, que se introduce directamente en la red de servicios públicos. Esto ahorra aproximadamente 350.000 litros de aceite de calefacción por año.

Regina Brückner, propietaria de la empresa de maquinaria textil de Leonberg, BRÜCKNER, está especialmente satisfecha con este exitoso proyecto entre RÖKONA y las empresas de servicios públicos de Tubinga: “Es agradable ver a nuestros clientes abriendo nuevos caminos y optimizando continuamente sus procesos. Para tener éxito en el mundo actual y poder soportar la competencia cada vez más dura en el futuro, necesitamos urgentemente una política comercial sostenible”.