Football game for fun

Right in time with the football world cup’s kick-off, the Mahlo soccer squad was also on the field. The veteran team of FC Hausen was the opponent, 3:1 the final score after 90 minutes. Surely, the colleagues that cheered from the sidelines had an important role in the victory. But most of all, fun and fairness were the main points for the match that was organized by the Mahlo works council. That became also clear, when Mahlonese Franz Ottl slipped on the jersey of the opposing team after an injury of one of their players and became an Hausen substitute. Very much in the spirit of sportmanship, both teams and their fans got together after the game for barbecue and drinks.




Innovating the world o Textiles – The Future of Printing

   Ride the digital printing wave with technologies that enable mass production and mass personalisation. View the latest ITMA 2019 webisode. Source smart solutions at ITMA 2019 – the world’s largest textile and garment technology exhibition.


At the Plast in Milan Mahlo answers questions about their quality control systems

Live on camera Michel Bruni, CEO of Mahlo Italia and Matthias Wulbeck, QCS Product and Sales Manager at Mahlo give insights on the Qualiscan QMS, the QCS system of Mahlo for Coating & Converting, Extrusion, Calendering, Nonwoven and Textiles.

Preeminent Exhibition for Plastics

The plastics production in Italy set new records in 2017. With a value of 4.5 billion euros, as many as 900 manufactureres employed 14 000 people. The export rate of 70 per cent of all goods shows that Italian plastic is purchased by converters all over the world who require high quality products.

Italian manufacturers of plastics and rubber processing machinery could be pleased with increasing sales to Germany, France and Spain, three traditionally strong markets. A jump in demands was also recorded for Russia with an increase of 109 per cent and for the African market with 22 per cent.

Now the Italian plastic industry is preparing for its most important exhibition. By gathering the whole industrial chain of plastic from raw material to finished products, PLAST is most prominent European event this year for the plastics and rubber industry. Over 1,100 exhibitors have registered, representing more than forty countries.

Get more information on PLAST by visiting

Film & Extrusion solutions from Mahlo

You are welcome to our booth 11 B 121 at PLAST 2018 in Milan, Italy. We will show you the latest technology of non-radiometric coating and film measurement. 

In the international Film & Plastics market we provide renowned on-line measurement and control solutions for film/sheet thickness, basis weight, density, coating add-on and moisture. You will find non-nuclear sensors plus responsive, professional technical support, and the most reliable, well-built scanning platforms in the industry.

Measurement without radiation protection requirements!

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.

Innovative coating & thickness measurement for extruded film!

Have you ever wondered how to measure thin layers and coatings straightforward and accurate? Whoever wants to measure thickness and coating of extruded film precisely can’t get past the quality controls systems of Mahlo!

Our team will advise you personally to all challenges posed by this topic.

Featured Mahlo products at PLAST

Qualiscan QMS 12

qms sensors – details

Gravimat DFI

Basis weight / thickness

Product highlights

  • Intelligent sensor with ultrafast microprocessor for preprocessing measurements
  • Precise measurements as a result of using extremely efficient beta radiation detectors
  • Four temperature-compensation sensors along with air pressure compensation

Customer benefits

  • Non-destructive, continuous determination of the weight per unit area of product webs
  • Highly stable and accurate measurement along with a minimum need to calibrate
  • The DFI allows wider measurement gaps and avoids damage to soft webs or wet coatings

Transmission of beta rays

The weight monitoring and control system measures the weight continuously, without contact, destruction-free and on moving product. The measurement is based on the attenuation of rays from a radioactive isotope through the substrate located in the measuring gap. This attenuation in intensity is an indication of the weight of the product.

The Gravimat uses a target weight to reduce the range of different m2 weights and thereby ensure a more consistent product.

Product highlights

  • Modern construction with intelligent sensors and traversing frames
  • Based on industry standard hardened computers running Windows embedded operating system
  • Components communicate through digital interfaces

Customer benefits

  • 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

Web process control

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


Double the success for KARL MAYER in India

A lucrative marketing initiative – KARL MAYER participated in the VDMA Symposium and held its own Tricot Circle in May 2018

India is an important market for KARL MAYER. In 2015, this country in Southeast Asia ordered more machines than ever before from this global company, which makes it one of its three most important sales regions.

Business is taking off again after rather muted demand over the last two years. “India has a population of about 1.3 billion, who all need clothes,” says KARL MAYER’s Sales Manager, Mark Smith, when highlighting the simple truth about what is driving the Indian economy. This country is growing and KARL MAYER is in an ideal position to support this development.

Attentive listeners – the auditorium at the Tricot Circle in Daman

As well as offering high-speed machines, KARL MAYER can also offer its Indian customers expertise in warp knitting and new ideas for textile products. For example, KARL MAYER continues to participate as a speaker in the symposia held by the Verband Deutscher Maschinen- und Anlagenbau e.V., VDMA (German Engineering Federation). The conference entitled “German Technology meets Indian Textiles and Nonwovens” took place recently on 15 and 16 May 2018 in Mumbai.

KARL MAYER also regularly organises its own Tricot Circle events there. Indian textile specialist were once again invited to gather inspiration for new ideas from the latest developments in warp knitting on 17 May in Daman and on 18 May in Amritsar.

Innovations from Germany

The VDMA Symposium in India included 36 application-oriented papers presented by more than 30 well-known companies. KARL MAYER was showing its TERRY.ECO concept for warp knitting. This system for the ecological and economical production of terry goods went down well with the visitors. There were about 100 delegates in the auditorium, including many representatives from weaving companies. “The feedback was much better than we expected. Many questions were asked, which showed that weavers have understood the advantages of warp knitting for producing terry goods and are now getting to grips with the possibilities,” explained Mark Smith, a speaker from KARL MAYER.

Know-how for tricot customers

The 3rd Tricot Circle held by KARL MAYER was well attended by just under 135 delegates. Visitors came from every part of the country and some even travelled five hours by car to be there.

The focal topics of the event were the possibilities offered by high-speed tricot machines for designing a wide variety of apparel fabrics and for producing terry goods.

Many warp knitting companies in India are concentrating on producing embroidery grounds and simple fabrics for saris. However, the HKS 4-M EL can do so much more than that, as Klaus Schulze showed in his lecture. This specialist in textile product development at KARL MAYER demonstrated various transparent fabrics featuring different mesh patterns in the ground and superimposed geometric designs produced by the versatile HKS model. Possible ground constructions include classic tricot types, such as honeycomb, diamond and atlas mesh construction. Atlas and filet tulle grounds featuring integrated diamond patterns with the look of raschel-knitted fabrics can also be worked. The delegates listened very intently to what was being said and asked many technical questions. “The patterning possibilities of the four-bar HKS machine will make it popular in India,” says Mark Smith with some certainty. But a new collection of designs produced on the HKS 3-M also attracted a great deal of attention. The lightweight, voile-like fabrics are particularly eye-catching, thanks to their fine, transparent ground and dense, striped pattern blocks, and gave the visitors ideas on how to use the potential of their machines even more effectively. The HKS 3-M is already extremely well established in India.

As another highlight, Klaus Schulze demonstrated the possibilities of producing warp-knitted terry fabrics. The TM 4-TS EL is particularly interesting for this textile nation. The delegates were also interested in a paper describing a beach towel made from a double-face fabric with a cotton side for drying and a side made from polyester microfibres with cut-open loops and a colour-printed design for lying on.

Other topics also generated great deal of interest and raised many questions, including innovative textile products manufactured on the HKS machine range for the athleisure sector, intelligently designed, stylish RSJ fabrics for sportswear and leisurewear, and KARL MAYER’s Virtual Showroom.

KARL MAYER’s representatives were optimistic from the feedback they received from the delegates and the conversations they had with them during the breaks. “The market will probably recover in 2018/19,” concluded Klaus Schulze.

KARL MAYER organised the event with the support of its regional agent, A.T.E.

LACE.EXPRESS lace with bourdon cord

Vein-like patterns produce a vibrant design

The OJ 59/1 B and OJ 83/1 B LACE.EXPRESS models are the latest technical innovations in jacquard multibar raschel machines from KARL MAYER, a company that is developing its lace products all the time. A pattern was developed in time for the ITM exhibition in April 2018 in Istanbul, which allowed the LACE.EXPRESS to demonstrate all its special features when processing bourdon cord. The non-stretch, all-over lace is intended for use in apparel. Its decorative, scalloped edges can be used directly for the hems of dresses, skirts and tops. The scalloped design is continued into the lace fabric to create decorative, floral motifs in a striped arrangement. The flowers and leaves are interpreted graphically and arranged on a ground that is patterned with different designs. Narrow net patterns, organic structures and open-pored holes create a dynamic design ensemble in the ground. The types of yarns used make the design appear to move. A combination of semi-matt, textured and shimmering yarns creates an eye-catching look with contrasting and surprising effects. Bourdon cord also creates a three-dimensional effect in the surface and is representative of a new trend. Liners with an embroidered look and 3D effects are still popular for fashion lace, but a high level of know-how and expertise are needed to produce them. Polyamide yarns in a count of 1/40 f 9 were used for the pillar stitches and for incorporating the bourdon cords, which have a count of about 1,600 denier.

The yarns were processed on an OJ 59/1 B in a gauge of E 24. The LACE.EXPRESS is also available in a gauge of E 18, so that it can also be used to process thicker types of bourdon cord.

KARL MAYER’s FILESIZE is gaining ground in China in the production of printed circuit boards

Good contacts to the CCL market   

Industry 4.0, e-mobility, 5G-neworks, the Internet of Things – the modern world is changing all the time and needs one thing above all else – electronics. The huge demand for electronic components is generating good business for the printed circuit board industry and its supply chain. Huge amounts of money are being invested in this sector, especially in China. Most of all the Copper Clad Laminates (CCLs), which are the copper-laminated precursors of printed circuit board production, are supplied by Chinese companies.

Woven glass fabrics are mainly used as the carrier material in the production of CCLs. These technical textiles are treated with resin and then coated on one or both sides with a copper layer. The metal coating is subsequently etched, depending on the design of the final printed circuit boards. Products referred to internationally as printed circuit boards (PCBs) are produced, onto which electronic components can be applied or they can be combined to produce multilayered circuit boards. Types having up to 48 layers can be used in computers. Computers, mobile phones and other electronic devices are becoming smaller all the time, so that the components used inside them are also becoming smaller. The trend towards miniaturisation and the increasing demand for flexible CCL types require finer and finer woven glass fabrics. Glass yarns having increasingly smaller counts have to be processed to meet this demand – a challenge that is making KARL MAYER’s warp preparation machines the machines of choice in China.

Experience on the Chinese glass market

KARL MAYER, the well-known textile machinery producer, has been operating successfully on the Chinese woven glass fabric market with its sizing and warping machines. At the end of 2016, the electronics supply industry really started to take off and the first big orders were placed. This was followed by more big orders in the autumn of 2017 which, according to Oliver Posselt, a Sales Manager, was completely unexpected. “With the first wave of orders, we were starting from a position of a modernisation backlog in the sector,” says this sales expert in the Chinese market. “This recent demand accounts for the optimism of manufacturers. Companies are convinced that this trend will continue.” Prospects are good for 2018 and 2019 as well. The buyers include many existing customers, who are expanding or upgrading their capacity, but also companies that are new to the woven glass fabric sector.

Clean size application and gentle yarn handling

KARL MAYER owes its success on the glass market to its sophisticated warp preparation process. This process uses the principle of single end sizing: the yarns are taken off from bobbins, fed through the sizing bath, dried, and wound onto beams. These are then assembled to produce warp beams for weaving. KARL MAYER can supply the right machine technology for every processing stage. In the initial stage, the glass rovings are gently removed from creels with the aid of the ACCUTENSE computer-controlled, hysteresis yarn tensioner and fed to the FILESIZE sizing machine. This machine for processing filament yarns also focuses on process control without any loss of quality. It processes a maximum of just 800 yarns – fewer than full warp sizing machines. These do not come into contact during the treatment process, so that they are sized all over. The yarns, which are processed separately, cannot stick together in the drying zone. The separation process, which normally has to be carried out when sizing full warps and which frequently damages the glass fibrils, is now superfluous. The FILESIZE also scores points with its accurate yarn tension control during yarn transportation – an important feature, since the non-stretch glass yarn cannot tolerate any fluctuations in tension. If the tension decreases, there is a danger of loose yarns, whereas if it is too high, the yarns can be damaged. To rule this out completely, the yarn tension is monitored and controlled at several places, such as in the size box and at the entry and exit points of the drying stretch.

The zone for removing the water from the glass comprises a modern hot-air oven and a subsequent drying cylinder zone. It is important to carry out pre-drying in the hot-air oven to enable the flat cross-section of the wet yarn to take on a circular shape. The temperature of the drying cylinders is 90 to 145°C and it is monitored and controlled accurately. This accurate temperature control is needed to guarantee top processing quality and for the sectional warp beams to have a high sized quality. Four to six sectional beams are then combined to produce the warp beams destined for weaving. KARL MAYER can supply the AMR for this process. This assembly machine operates efficiently and accurately, and has proved itself many times worldwide in warp preparation.

Maximum productivity

In addition to meeting the highest quality requirements, the FILESIZE operates at an exceptionally high level of productivity. This is due to its exceptional operating reliability and unique output. This warp preparation machine operates at an impressive rate of 250 m/min-1 when processing glass under practical conditions.

Suitable for processing the next generation of fine glass yarns

The warp preparation sequence for processing glass can be adapted flexibly to suit the intended end-use, especially in terms of the tension regulation and the arrangement of the drying zone. For example, the number of drying cylinders can be varied as a function of the yarn count. “Five cylinders are usual for average counts, whereas three are sufficient for very fine counts,” explains Oliver Posselt. The coarsest types that still need to be sized have counts of 75 tex. He goes on to say, however, that fine yarns are more interesting and in higher demand. “Our customers are currently talking about 5 tex down to 1.3 tex. The challenges associated with this require a completely new type of technology. We are in an excellent position to lead the way here,” says this Sales Manager. A machine for processing extremely fine glass yarns was successfully installed in February 2018. Experience with processing these fine yarns was also gained during a project that involved the upgrading and modification of older machines.

NICE TO MEET YOU, MAI – Marketing staff member Stephanie Marchsreiter visits subsidiary Mahlo America Inc.

Marketing staff member Stephanie Marchsreiter visits subsidiary Mahlo America Inc.

Ready for take off

Well, now the time has come: after being almost a year with the department for Marketing and Media Relations, my first trade show visit lies ahead. The NPE in Orlando is my destination, one of the most important exhibitions in the plastics industry worldwide. To get there, a 12 hour journey is inevitable. The trip starts in Munich with a short layover in Frankfurt. The plane ride only takes 35 minutes; I need almost as much time for getting from one gate to the other.  Here, you truly can see that FRA is Germany’s biggest airport. Luckily the flight is on time, so the journey can begin. The ten hours across the pond go by quicker than I hoped and we are already touching down in Orlando. Here, sunshine and 32 degrees are waiting for me. The entry also goes smoothly, a taxi is found quickly, too. Now off to the hotel so that I am ready for NPE the next day…

More on this later… :-)

Welcome to NPE

The Mahlo-Team at NPE

First thing in the morning, I meet all the other Mahloneses:Alan Lavore, the Executive Vice President of Mahlo America Inc., Eric Reber, David Jillson and Frank Fei. Together, we drive to huge exhibition center. The NPE has been in full swing for two days already and lasts another three. The complete plastics industry is meeting here, from extruders over equipment providers to end users. Looking at the rush at the Mahlo booth, you can see that we made a name for ourselves in the US market. Many company key holders have concrete questions regarding their application and the best Mahlo solution for them. The team has its hand full all the time.

Regardless, the Technical Sales Manager Eric Reber takes the time to tour the trade show with me. He explains different production processes to me, where our products come to use, and shows me the booths of our partners and competitors.

But the end of a trade show day doesn’t necessarily mean the end of the day. One evening, for example, we go out for dinner with long term clients in a delicious seafood restaurant. Why not combine business with pleasure?

Visit to Seaworld


Because the last day of a trade show is usually a slow one – some exhibitors already begin to dismantle their booth – Alan Lavore, the Executive Vice President of Mahlo America Inc. – gives me a day off. And what are you going to do in Orlando?

Right! You visit one of the numerous amusement parks. I choose Sea World. The park is a mixture of oceanarium, featuring sea lions, dolphins and killer whales, and theme park with different roller coasters and shows. Riding them is as much fun as watching the fascinating show with their famous orcas.

Is it Flipper?
Posing for some pictures?

Goodbye Orlando – Hello Spartanburg

After exciting days at the trade show, now we are off to the Mahlo America Inc. headquarter in Spartanburg. Are the other colleagues as nice as the ones I already know? How does a typical American workday run? That’s what I’m most curious about. The first question is answered easily with yes! The welcome is warm and friendly, the famous “Southern hospitality” palpable from the beginning. That continues over the next days. I’m included in all lunch plans; furthermore, my colleagues Ann, Mary and Mary make sure to introduce me to Krispy Kreme Donuts. One of the THE sweet sins here in the South.

The work day is – not totally surprising – similar to a German one. Especially after a week at the trade show, everyone has their hands full. Nevertheless, my co-workers have time for my questions: John explains how the service works here, Mike shows me the Pilot Line with which client samples are tested. Everyone identifies with Mahlo and is fully committed to the company, in some instances for more than 20 years. So there surely is enough material for up-coming stories! With so many new impressions, the week flies by, and before I know it, it is already time to say goodbye. I’ve met so many nice and generous people here that I hopefully have not seen for the last time.  

So with this in mind: Take care Spartanburg, see you!