Tonello strikes again. And it does so both concretely and resoundingly, choosing, once again, to distinguish themselves on the market as a producer of ideas even more than a producer of machines and processes.

We’ve dedicated this area to research and experimentation, with the invaluable collaboration of a “guru” the likes of Piero Turk. It’s a space that is the direct offshoot of our Research Centre, which has been appreciated over the years for its ability to churn out sustainable, energy-saving, and healthy-garment innovations (ECOfree, NoStone®, and Core are very significant names for experts in the sector).

All this at the service of our customers, brands and designers, who, with the support  of our company’s technicians and researchers, are able to transform their ideas into reality, experimenting, using trial and error to perfect treatments, special effects, and washes; inspired by the evolution of fashion, breathing history, reliving the past to reinvent the present and imagine a future of freedom and fantasy.

And this creative area will also become a real school, a craft shop, where real training will take place, and where the “masters” of denim can meet and pass on their wealth of experience and knowledge.

With the foresight and practicality that has always marked the company, Tonello has once again aimed high, aware of its unique know-how and the authority gained in over 35 years of presence on the world market in the service of “Made in Italy”.

In the Tonello Atelier, in short, the garments in the gestational stage can see the light. They can be analyzed, studied, optimized, changed, and tested: the complete view of all treatments will allow the exploration of the many technological possibilities and the thousands of special effects that, with Tonello machines, have become absolutely normal.

“This new creative area”- says Alice Tonello, R&D manager of the company – “is the natural outcome of our philosophy: a concrete service for our customers that goes beyond the simple fact of being a manufacturer of machines.”

Building for the future with KARL MAYER

Textile-reinforced concrete – the theme of KARL MAYER’s presentation at TECHTEXTIL, to be held in Frankfurt from 9.-12.5.2017, stand 3.0/E 18

KARL MAYER manufactures textile machines for producing the products that are used in many cutting-edge applications. These products can be seen at the Frankfurt site on stand 3.0 / E 18. Here, the visitors can expect an impressive display focusing on textile-reinforced concrete and functional clothing for the sports and athleisure sectors.

Strong solutions for composite materials

Textile reinforcing materials offer better ecological and economic alternatives to steel reinforcements when building with concrete. Since textiles do not rust, only a thin covering material is required. This saves on resources, reduces environmental pollution and also enables thin-walled, filigree designs to be produced. KARL MAYER Technische Textilien GmbH (Technical Textiles) can offer the RS MSUS-G weft-insertion warp knitting machine for producing the textiles that are used as an innovative way of reinforcing concrete. This high-speed raschel machine with weft insertion in line with the stitch courses can produce heavy carbon-fibre grids (Figs. 1 + 2), which are used by members of TUDALIT e.V. This association is responsible for the TUDALIT® trademark-protected brand for maintaining quality standards in the production and use of textile-reinforced concrete. Allgemeine bauaufsichtliche Zulassung (General Building Regulations Approval) has already been applied for to cover certain concrete components containing weft-inserted, warp-knitted textiles.

The textiles produced on the machines manufactured by KARL MAYER Technische Textilien can be used to reinforce the composite materials used in concrete construction, as well as plastic composites. Here, ready-consolidated, fibre-thermoplastic, semi-finished products, so-called organic sheets, have become more important in recent years. According to Jochen Schmidt, the Managing Director of KARL MAYER Technische Textilien GmbH, the concept of fibre spreading is also starting to be a hot topic. Before they are joined to the plastic matrix, the fibre tapes are spread using KARL MAYER’s UD 500 and UD 700 fibre spreading machines. These two machines have already made a name for themselves among composites’ manufacturers for use in the preliminary stages in the production of multiaxial textiles.

High-performance, warp-knitted textiles maximise performance and comfort in the sports and athleisure sectors

Innovative sports- and athleisure-wear provides comfort, enhances performance, looks stylish and offers a performance profile that is backed up by intelligently designed textiles. Stylish, functional stretch and non-stretch textiles are a speciality of KARL MAYER’s warp knitting machines. The company’s high-speed tricot machines, jacquard raschel machines and double-bar raschel machines can produce a variety of structured and openwork designs (Fig. 3) from a single source, and also work functional zones that can be integrated into a garment, such as a jersey. Zones are created, which provide a defined compression, breathability, warmth retention and freedom of movement. This is based on body mapping principles and the zones are located in exactly the right places. KARL MAYER’s double-bar raschel machines in particular are also setting functional trends when producing seamless items that are making quite a fashion statement.

With its impressive stand design and carefully selected exhibits, KARL MAYER is looking forward to a successful show. “Alongside JEC World, Techtextil is the most important trade fair for us,” explained Jochen Schmidt. “We meet many of our customers there, who are frequently exhibitors themselves, and we are also expecting to have some interesting conversations with people who are visiting us the first time.”

KARL MAYER – Sophisticated technology for a rustic denim look

KARL MAYER launches the PRODYE-R – a customised dyeing machine for the rope dyeing process

Jeans are the perennial evergreens of the clothing sector. Their characteristics and looks change all the time, so that they are always on trend. The different appearances are created by different production techniques – particularly by the dyeing processes involved.

Whereas fabrics for fashion denim are normally dyed by the slasher-dyeing process, fabrics that are used for producing classic American blue jeans are dyed using the rope dyeing process.KARL MAYER can supply the most suitable dyeing technology for both processes in the shape of its PRODYE system, which has already become very well established on the market. As far as slasher-dyeing technology is concerned, this well-known company leads the market in the fashion denim sector. In the last three years, KARL MAYER has delivered eight machines only to Turkey. For some time now, the company has been working hard on developing new rope dyeing applications, especially in this traditional denim-producing country

Technological advantages of the slasher-dyeing line for the rope dyeing process

The PRODYE technology combines the technical achievements of three years of development work at KARL MAYER, and delivers maximum performance during indigo dyeing. Compared to similar systems available on the market, this innovative technology reduces water consumption by roughly 30% in practice, decreases yarn wastage, and produces deeper indigo shades during the slasher-dyeing process. What is more, the productivity is almost twice as high when processing lightweight denim. With this type of product, customers can achieve an output of up to 70 m/min.

This unique performance is the result of a number of technical features, including the Double Vario dyeing unit (Fig. 1). This application system is the key element of the PRODYE system. Its optimised flow patterns and efficiency result in flexible and process-specific immersion lengths and times during pretreatment and dyeing. The technical features of the Double Vario include a well-thought-out cross-flow system for perfect dyebath circulation and an integrated system for raising the immersion rollers. The latter simplifies handing, minimises cleaning times and guarantees stable liquor baths during machine downtimes. An integrated, indirect heating system also enables a range of dyeing techniques, such as reactive, sulphur and indanthrene dyeing, to be carried out reliability and flexibly. Finally, squeeze roller pairs operating at 100 kN, which are harmonised with each other, at the end of the processing sequence in the dyeing machine guarantee uniform fabric transport and avoid variations in the circumferential speed at the textile material. The design of the Double Vario has been optimised to enable it to be integrated into the PRODYE-R rope dyeing system.

Complete solutions for the rope dyeing process

As well as the actual dyeing technology, KARL MAYER can also supply all the other machines and equipment needed for rope dyeing. The full one-stop package consists of various creels, the BALL WARPER (Fig. 2), the LONG CHAIN BEAMER (Fig. 3) and the PROSIZE® sizing machine.

The BALL WARPER forms the ropes for producing beams having a maximum diameter of 1,500 mm and operates in a controlled, tension-regulated, gentle and precise way. The technical features that are responsible for improving performance include, for example, pneumatically controlled disc brake technology for synchronous braking, and an integrated suction system for removing fly and other contaminants. Removing these impurities reduces contamination during wet treatment.

The LONG CHAIN BEAMER produces beams having a maximum diameter of 1,000 mm. A pneumatically operated, self-centring, toothed, sharply tapered beam mounting and an infinitely adjustable presser roller device, including an automatic kick-back facility, guarantee reliable processing and easy handling. The latter guarantees perfectly cylindrical beam winding. An integrated, reverse-driven compensator also enables the operating status during rope feeding to be changed at constant rope tension levels.

The PROSIZE® sizing machine operates with the new VSB Size Box, and the sizing result guarantees first-rate efficiency during weaving. Its advantages include compact yarn feed, short yarn paths, accurate process control, and a high level of reproducibility. The PROSIZE® is also easy to operate.

Making more room for pioneering work – KARL MAYER

A large number of visitors attended the ceremony to celebrate the opening of NIPPON MAYER’s Development Centre, 01.–03.03.2017 in Fukui

Progress needs new ideas, know-how, equipment and plenty of room to develop, which is why KARL MAYER opened a new Development Centre recently in Japan. Setting up the modern building was part of a restructuring programme implemented at KARL MAYER’s site in Fukui, Japan.

The restructuring and modernisation programme involved the setting up of a Centre of Excellence at this subsidiary between 2014 and 2016 for developing double-bar raschel machines and for researching into new innovations for the textile sector. NIPPON MAYER was able to demonstrate what it has to offer at an in-house show, which was held from 1 to 3 March 2017. This customer event is one of a series of celebrations, which will be held to mark the 80th anniversary of the KARL MAYER Group, and the occasion was used to officially open the recently completed Development Centre. This get-together, together with the inauguration ceremony, tour of the company, machine show and workshops, was extremely well attended.

“We were able to welcome more than 400 visitors. We did not expect such a high level of interest,” concluded Armin Alber. The President of NIPPON MAYER was not only delighted with the number of guests, but also with the wide spectrum of their business backgrounds. The group was made up of many customers from Japan and included a large delegation from Korea and even Europe. They were representatives of brand-name manufacturers from the sportswear and lace sectors, institutes and universities, as well as textile retailers, managing directors and owners of textile companies, who have not yet got into the business of warp knitting. Following the programme of events, they were all impressed by the modern set-up and innovative strengths of KARL MAYER’s Japanese subsidiary. “The building and equipment in our Development Centre and assembly hall impressed our guests and reinforced their confidence in our Japanese location,” said the Senior Director, Hirokazu Takayama. By holding this event, NIPPON MAYER has shown that it does not only supply high-end machines but that it is also a partner that can put new ideas into practice – for generating new business.

Innovative technology for producing sportswear and clothing

A selection of double-bar raschel machines formed the focal point of the well attended technical presentation. The specialist machines for producing seamless articles are ideal for manufacturing sportswear and clothing, and can produce a wide range of different patterns. The presentation of this innovative technology led to some intense discussions, especially among sportswear manufacturers. The HKS 4-M EL also generated a great deal of interest as it was operating. In full view of the impressed visitors, this high-speed tricot machine was producing a multicoloured garment piece featuring various designs with non-stop changeover facility. It was reaching a speed of 2,100 min-1 and, despite its high speed, was also extremely accurate.

The DS OPTO, which was also being demonstrated next to the tricot machine, also attracted the attention of the observers. This direct warping machine produces patterned sectional warp beams (SWBs), which enables the HKS 4-M EL to achieve its full performance potential. The DS OPTO operates in sectional warping mode when producing coloured SWBs at a high level of efficiency, as well as when processing short warps for developing new products. This hybrid machine can also be used just as easily for direct warping at high speed.


ICE EUROPE 2017 21 – 23 March 2017 in Munich, Germany


21 – 23 March 2017 in Munich, Germany

Visit Mahlo at booth A5/1012

ICE Logo

International Coating & Converting Exhibition Europe

Your are very welcome to our stand in hall A5 booth no. 1012 at ICE in Munich. Experience live the latest technology of non-radiometric coating measurementin operation.

In the Coating & Converting market we provide renowned on-line measurement and control solutions for film/sheet thickness, basis weight, density, coating add-on, and moisture.


The Mahlo Team of ICE 2017 in MunichThe Mahlo Team of ICE 2017 in Munich

Well done - a beautiful stand again
Well done – a beautiful stand again
As we can see plainly: Basis weight is a weighty topic for Mahlo at the ICE
As we can see plainly: Basis weight is a weighty topic for Mahlo at the ICE
It's all about automation and web process control, on-line. Naturally.
It’s all about automation and web process control, on-line. Naturally.
Oh yes, and quality control solutions for coating & converting. We'll meet your needs. Check it out!
Oh yes, and quality control solutions for coating & converting. We’ll meet your needs. Check it out!
Qualiscan QMS-12 - Our traversing quality control system measures up to 5 different tasks in one stroke. On-line and over the complete web width.
Qualiscan QMS-12 – Our traversing quality control system measures up to 5 different tasks in one stroke. On-line and over the complete web width.
On display: Compact O-frame Webpro XS with an X-ray basis weight sensor Gravimat FMX-T
On display: Compact O-frame Webpro XS with an X-ray basis weight sensor Gravimat FMX-T

Control & Display Station of the Qualiscan: Profile and 2D-Profile of the measurement at a glanceControl & Display Station of the Qualiscan: Profile and 2D-Profile of the measurement at a glance

How thin is the line?

The UniScan M or UniScan S traversing frames are the single-sided counterpart to the double-sided O-frames of the WebPro series, and have been specially designed to accommodate the single-sided sensing devices of the Mahlo QMS family.
Have you ever wondered how to measure thin layers and coatings straightforward and accurate? Then come along at our booth!

Want to experience traversing white light interference measurement? Then come along at our booth!

Measurement without radiation protection requirements!

Our project manager for QCS Matthias Wulbeck and his team will advise you personally to all challenges posed by this topic.

The traversing quality control system Qualiscan QMS is the perfect tool for the demanding manufacturer. It offers non-nuclear sensors plus responsive, professional technical support, and the most reliable, well-built scanning platforms in the industry.

The Qualiscan QMS can be used in industrial sectors in which products are produced as a web, like

  • Coating & Converting
  • Film & Extrusion
  • Nonwoven
  • Textile
  • Pulp & Paper
  • and many more …

 For detailed information about the trade show itself please visit the website of the ICE Europe 2017:

Featured Mahlo products at ICE Europe


QUALISCAN QMS-12  :  Traversing quality control system


Qualiscan QMS-12
Qualiscan QMS-12

The Qualiscan QMS is a modular system for measuring, logging and controlling critical process parameters over the entire width of the product, including weight per unit area, coating weight, thickness, moisture etc.

The Qualiscan QMS can be used in virtually every industrial sector in which products are produced as a web, or where they are finished (laminated, coated, etc.). The versatile sensors and measuring devices of the Qualiscan QMS series can sense, log and continuously control such parameters as weight per unit area (basis weight), coating weight, thickness and moisture in a variety of web-type products.

The Qualiscan QMS is a modular system consisting of multiple measuring sensors and traversing frames acting as intelligent nodes on a network. The individual components are linked through a normal Ethernet cable as found in any office for networking multiple PCs.


Product highlights Customer benefits
  • Modern construction with intelligent sensors and traversing frames
  • Based on industry standard hardened computers
  • running Windows embedded operating system
  • Components communicate through digital interfaces
  • Savings in raw materials and/or energy at the manufacturing stage
  • Uninterrupted monitoring and logging of actual product quality
  • Improvement in product quality, especially in conjunction with control


Product information (PDF)


Da un estratto di Wikipedia the free encyclopedia:

According to textile historians, chenille-type yarn is a recent invention, dating to the 18th century and believed to have originated in France. The original technique involved weaving a “leno” fabric and then cutting the fabric into strips to make the chenille yarn.

Alexander Buchanan, a foreman in a Paisley fabric mill, is credited with introducing chenille fabric to Scotland in the 1830s. Here he developed a way to weave fuzzy shawls. Tufts of coloured wool were woven together into a blanket that was then cut into strips. They were treated by heating rollers in order to create the frizz. This resulted in a very soft, fuzzy fabric named chenille. Another Paisley shawl manufacturer went on to further develop the technique. James Templeton and William Quigley worked to refine this process while working on imitation oriental rugs. The intricate patterns used to be difficult to reproduce by automation, but this technique solved that issue. These men patented the process but Quigley soon sold out his interest. Templeton then went on to open a successful carpet company that became a leading manufacturer throughout the 19th and 20th centuries.

In the 1920s and 1930s, Dalton in Northwest Georgia became the tufted bedspread capital of the US thanks to Catherine Evans (later adding Whitener) who initially revived the handcraft technique in the 1890s. Hand-tufted bedspreads with an embroidered appearance became increasingly popular and were referred to as “chenille” a term which stuck.[1] With effective marketing, chenille bedspreads appeared in city department stores and tufting subsequently became important to the economic development of North Georgia, maintaining families even through the Depression era.[1] Merchants organised “spread houses” where products tufted on farms were finished using heat washing to shrink and “set” the fabric. Trucks delivered pattern-stamped sheets and dyed chenille yarns to families for tufting before returning to pay the tufters and collect the spreads for finishing. By this time, tufters all over the state were creating not only bedspreads but pillow shams and mats and selling them by the highway.[1] The first to make a million dollars in the bedspread business, was Dalton County native, B. J. Bandy with the help of his wife, Dicksie Bradley Bandy, by the late 1930s, to be followed by many others.[1]

In the 1930s, usage for the tufted fabric became widely desirable for throws, mats, bedspreads, and carpets, but not as yet, apparel. Companies shifted handwork from the farms into factories for greater control and productivity, encouraged as they were to pursue centralized production by the wage and hour provisions of the National Recovery Administration’s tufted bedspread code. With the trend towards mechanization, adapted sewing machines were used to insert raised yarn tufts.[1]

Chenille became popularized for apparel again with commercial production in the 1970s.

Standards of industrial production were not introduced until the 1990s, when the Chenille International Manufacturers Association (CIMA) was formed with the mission to improve and develop the manufacturing processes.[2] From the 1970s each machine head made two chenille yarns straight onto bobbins, a machine could have over 100 spindles (50 heads). Giesse was one of the first major machine manufacturers. Giesse acquired Iteco company in 2010 integrating the chenille yarn electronic quality control directly on their machine. Chenille fabrics are also often used in Letterman jackets also known as “varsity jackets”, for the letter patches.