Highsun And KARL MAYER — Teaming In The Direct Warping Sector

OBERTSHAUSEN, Germany — July 30, 2018 — Highsun has made a name for itself as one of the world’s largest company groups specializing in the polymerization and spinning of polyamide and in the production of spandex. The Chinese group focuses on high-quality products and on new innovations. Providing effective support for its end customers in the polyamide and elastane fiber production chain is also important for this synthetic fiber specialist.

The Highsun Group is a modern conglomerate, which combines business operations in synthetic fibers, real estate and financial services under a single umbrella.

The synthetic fiber operation employs roughly 5,000 people. The core products include Nylon and spandex yarns, as well as polyamide 6 polymer chips. Highsun also offers one-stop solutions for the textile industry. These include supplying caprolactam as the starting material for the production of polyamide 6, polyamide itself, and spandex, as well as spinning, yarn texturing, direct warping and, last but not least, dyeing and finishing. 40 billion RMB were invested in its subsidiary, Shengyuan New Materials, as a high-end facility for producing caprolactam. This company covers an area of roughly 549,000 m². Its planned annual output is 1 million metric tons and the machinery for producing the first 400,000 metric tons was successfully installed and launched into production in July 2017.

Environmental protection is a top priority for Highsun in all its business operations. Its products are certified in accordance with the OEKO-TEX® Standard 100. They are sold on the domestic market but are also well established globally. Among its customers are textile companies in 30 countries, mainly in Asia, Europe and North and South America.

Experience and expertise in warping

Alongside Shengyuan New Materials, Highsun Warping plays an important part in complementing the range of products for producing polyamide and spandex, i.e. in the processing chain. This arm of the group supplies sectional warp beams of the highest quality to improve the product quality in warp knitting. This is achieved by using high-speed machines and having extensive knowledge and expertise.

Highsun relies on many years of experience in direct warping. An early subsidiary of the company, the GuiFuRen Company, began warping spandex in 1994 using one of the first elastane warping machines supplied by Karl Mayer. In the years that followed, Highsun continuously expanded its research and development operations and improved its product quality. With its high-end, innovative products, Highsun won many customers and set up a number of long-lasting partnerships.

Managers in warp knitting companies were increasingly coming to the conclusion that high-quality warp beams could have a clear, positive influence on their production, but they also knew that extensive experience, technical knowledge and innovative machines were needed. Many warp knitting companies could not meet these requirements, which restricted the development of their businesses.

For this reason, in 2011, Highsun invested in a large number of Karl Mayer’s warping machines for processing warp beams with elastane yarns, and set up its own warp knitting and warping department. Its customers could obtain high-quality warp beams for warp knitting direct from Highsun. Warp knitting companies were keen to exploit this facility, which consequently promoted the expansion of the Highsun Group.

A machine with an impressive performance

20 of Karl Mayer’s elastane warping machines, types DSE HH and DSE 21/21 EC, are currently running in Highsun’s factories. Yarns having counts of from 18 to 640 den can be processed on these warp preparation machines, and beams carrying between 30 and 1,090 warp yarns can be warped. The company also invested in a number of DS 50/32 DNC direct warping machines at the end of 2017 to enable it to produce super-sized beams.

With its flexible and modern warping operations, Highsun can meet the needs of its customers most effectively. Deliveries within the area can be made in less than 24 hours after the order has been placed. This exceptional service and high warp beam quality have impressed many brand names, including Carvico. This well-known warp knitting specialist has been working with Highsun since 2017. The spandex beams are exported directly to Carvico’s factory in Italy and fully meet the stringent requirements of the company’s own quality assurance specifications.

Cooperation that benefits the customer

This Chinese company intends to continue cooperating with Karl Mayer in the future in order to fulfil its obligations as a reliable partner. “Highsun will strengthen and consolidate its strategic cooperation with Karl Mayer in the future. Our company group will continue to concentrate on the production of and research into top-quality polyamide and spandex, as well as high-end products to put us at the forefront of healthy development within the sector,” says Mei Zhen, general manager of Highsun Synthetic Fiber Technologies Co. Ltd, one of the companies in the Highsun Group.

As part of this partnership, Highsun employees and their warp knitting customers can attend courses held by the Karl Mayer Academy China. During these training courses, instructors and service specialists at Karl Mayer (China) provide the customers of both companies with useful information on setting up, operating and maintaining warp knitting machines. On 7 May 2018, a four-day course was again held in Highsun Synthetic Fiber Technologies Co. Ltd. Alongside of the warp knitting introduction given by Karl Mayer instructors, the Head of the warp preparation section there, Wang Wenyong, provided additional information by speaking about how to improve the warp quality and on the relationship existing between warp beam quality and warp knitting efficiency. “There is every reason to take part in the courses to enable us to promote the success of our mutual customers,” says Wang Wenyong.

Warping elastane on Karl Mayer’s DSE machines

The DSE HH and the DSE 21/21 EC produce warp beams from elastane and deliver an exceptional level of performance. Their vertical process management system enables even very fine yarns to be processed gently, the freely running yarn permits the machines to be operated easily, and the machines are extremely flexible in terms of the stretching conditions. Stretching of the warp yarns on the beam can be selected from between 15 and 100% and is adjusted in three stretching zones. In the pre-stretching zone, the yarn coming from the creel is stretched by between 50 and 210 percent. Following this, the yarns pass via a positively driven overrun roller system in an intermediate zone, where they can contract again. In the final stretching zone, the yarn is given its final stretch up to the winding point, and this may be between 15 and 100 percent.

GoLite produces ligthweight outerwear with a focus on running and yoga. A big focus is put on sustainability with garment made of recycled materials and sustainable chemistry.

A camera monitoring system interrupts the machine operation in the event of any yarn breakages. If the machine is stopped at full speed, a sophisticated system for synchronizing the brakes guarantees reliable control of the yarn sheet. A computer-based circumference control system ensures that all the beams in a set are absolutely identical.

Posted July 30, 2018

Source: KARL MAYER Textilmaschinenfabrik GmbH

ITMA Asia + CITME 2018 Exhibitor Preview: KARL MAYER

OBERTSHAUSEN, Germany — August 23, 2018 — Digitalisation and sustainability – the top themes of KARL MAYER’s presentation at ITMA ASIA + CITME, 15.–19.10.2018, stand B 11, hall 4, in the National Exhibition and Convention Center in Shanghai

KARL MAYER will be presenting its latest innovations at ITMA ASIA + CITME, which will be held from 15 to 19 October 2018. This global player is using its latest developments to tackle the changes taking place in the world today.

“The mega trends of digitalisation and sustainability are changing the world as we know it. As an innovative global market leader, we see these changes as an opportunity for our customers. At ITMA ASIA+ CITME, we will be showing our visitors how KARL MAYER is implementing these strategic themes, digitalisation and sustainability by delivering integrated solutions offering a wide range of advantages,” says KARL MAYER’s Managing Director, Arno Gärtner.

KARL MAYER can be found in the Exhibition and Convention Center in Shanghai on stand B 11, hall 4, where a new umbrella brand will be launched, offering innovative digital solutions known as the KARL MAYER Digital Factory, which was introduced last year. A look at KARL MAYER’s CLEANER.PRODUCTIONS will also be on the cards. Other highlights include a performance show of the latest generation of machines, a fashion show showcasing decorative, trendsetting fabrics, and a presentation of the Technical Textiles centre of excellence. An in-house show at KARL MAYER (CHINA) in Changzhzou will also be held at the same time as the fair, scheduled for 15 to 18 October.

Development of the best digital solutions

As a pioneer in textile machinery building, KARL MAYER is following a broad digitisation strategy. An important element of this strategy is to support its customers with new digital solutions at a market leader level.

The initiatives for this strategy are being coordinated by Antonia Gottschalk, the Head of Digitisation. The expertise for doing this is based on an efficient network. Since March 2018, KARL MAYER has been part of ADAMOS, an alliance made up of industrial and software companies. At the end of 2017, KARL MAYER also set up its own start-up company in Frankfurt, known as the Digital Factory, for developing new, innovative digital business models, products and services. In future, these will be combined under a new umbrella brand, which is being launched at ITMA ASIA + CITMA. “Management is focusing on the KM Digital Factory. Together with our involvement in ADAMOS, the new company will enable us to quickly make the best digital solutions available for delivering maximum benefit to our customers,” says Arno Gärtner.

Networked machines

Knowing what is going on and being informed at all times, regardless of where we are – mobile digital solutions have been making inroads into out daily life for many years now and, have changed our perception of what is current.

For the first time, KARL MAYER will present its own solution for networking its machines. This digital solution will provide its customers with transparency in real time regarding the performance of their machines, and can be used in the company’s own network with very little modification.

Integrated sustainability

“We care about your future” is what KARL MAYER is all about. Its philosophy is to take responsibility also for future generations. What KARL MAYER is doing to promote sustainability will be on show at the fair and on the internet at www.CLEANER.PRODUCTIONS.

The environmental aspects of this include the LEO® Low Energy Option, which should enable energy consumption during machine operation to be reduced by between 9.5 and 13 %, depending on the type of machine. Costs and CO2 emissions should be reduced at the same time.

Intelligent, end-use-applicable concepts should also reduce environmental loads, as a technology transfer project being carried out by the central government and regional authorities in Wujiang Shengze, China, is demonstrating. One of the aims of this project is to replace the environmentally harmful looms in this industrial area with KARL MAYER’s warp knitting machines offering a comparable product portfolio. The TM 3, with its broad product portfolio, is a particularly good alternative. This tricot machine will be shown in operation at the exhibition, together with examples of its uses.

KARL MAYER will be showing the TERRY.ECO concept for the environmentally friendly production of terry goods, the core element of which is the TM 4 TS-EL machine. Depending on the type of product being produced, this cotton terry warp knitting machine can produce up to 250 % more fabric and consumes approximately 87 % less energy per kg of textile than air-jet looms. Sizing can be dispensed with, which reduces energy, water and effluent loads. The TM 4 TS-EL will be on show at KARL MAYER’s in-house show in Changhzou.

With its PROSIZE® sizing machine, KARL MAYER is offering weaving companies involved in the production of terry goods a sizing machine based on the concept of sustainability. With this machine, the sizing agent is applied by a highly efficient, intelligent process. Compared to conventional methods, this reduces the consumption of sizing agents by up to 10% and reduces bath volumes. A reduced size consumption also means less energy consumption when preparing the chemicals and for desizing. Also, less effluent is produced. The core element of the PROSIZE® system, the VSB Size Box, will be on show in Shanghai.

The latest generation of machines

For the first time, the widest high-speed tricot machine in the world, the HKS 3-M, 280″ (Fig. 1), will be demonstrated to the public in operation at the exhibition. This new machine delivers maximum flexibility for the usual product repertoire. Unlike previously, articles of different widths and also more fabric webs can be produced simultaneously on just one machine. The unique performance of this machine will be demonstrated as it produces a velour fabric in a gauge of E 32.

The first TM model with KAMCOS® 2 facility is also being showcased. KARL MAYER’S TM 3, 186″, equipped with the next generation of the KARL MAYER Command System, retains the tried-and-tested features of the HKS version. These include an operator interface with functions based on smartphone technology and an integrated laser stop system as well as data access via mobile devices using the KARL MAYER CONNECT app. In Shanghai, this efficient, flexible production machine will be producing a tough fabric in a gauge of E 32 with ecological benefits. This textile can be used as a substitute for fabrics produced by water-jet weaving, with its high effluent loads.

For the warp preparation sector, KARL MAYER will also be showing the innovative VSB Size Box at the fair. Instead of the usual immersion and bath application process, the PROSIZE® (Fig. 2) operates with three, highly turbulent, homogeneous application zones, spray bar technology and a subsequent application/squeeze roller system. This reduces the volume of the size bath and sizing additives, thus decreasing the environmental loads. Other benefits include an extremely uniform size film and less fibre dust – guaranteeing maximum weaving efficiency – and a 20% larger yarn coating zone.

KARL MAYER will also be showcasing the ISODIRECT direct warping machine – a world first with a unique cost:benefit ratio. This all-round machine can process every type of staple-fibre yarn and produces high-quality beams at warping speeds of up to 1,000 m/min-1.

Textiles with trendsetting features

This demonstration of KARL MAYER’s technology and strategies will be complemented by a presentation of the wide range of applications of warp-knitted fabrics. Seductive lace, high-performance fabrics for sportswear, original creations for athleisure wear, and apparel fabrics with a certain pizzazz – KARL MAYER’s textile innovations show the wide variety of warp-knitted textiles available and are setting the trend in every sector.

Building on textiles

KARL MAYER has the right technology and expertise to cater for a wide range of applications in the technical textiles sector. The company’s weft-insertion, biaxial and multiaxial warp knitting machines can be found in the plants of manufacturers of inlays, tarpaulins and advertising substrates, as well as in those of producers of geogrids, composites and automotive fabrics. The focus of the exhibition at ITMA ASIA + CITME will be on textiles for the construction sector. The Chinese construction sector is one of the growth areas in the country but, unlike the construction industries in Europe and America, for example, the Chinese building industry focuses on conventional materials. Textiles can offer the construction sector many advantages, especially when used in concrete components. By replacing conventional steel reinforcements with carbon- or glass-fibre textiles (Fig. 3), the amount of concrete used can be reduced by up to 70%. Other promising applications for warp-knitted structures are in tear-resistant plaster grids for increasing the tear resistance within the plaster, self-adhesive tape for repairing holes and cracks in walls, cost-effective, flexible roof canopies and bitumen roofing materials with excellent mechanical properties. Examples of these types of textiles will be used to illustrate the advantages of warp-knitted building textiles during the exhibition.

An in-house show with exclusive machines

KARL MAYER (CHINA) is sending out invitations to attend an in-house show with performance demonstrations of selected machines for the Chinese market from 15 to 18 October in Changzhzou.

The new COP 5 M-EL, 180″ (Fig. 4) five-bar tricot machine will be unveiled to the public for the first time in Changzhzou. This machine will be producing a shoe fabric in a gauge of E 20, just one of the fabrics in its extensive production repertoire. The electronic guide bar control facility and five guide bars make the machine extremely flexible.

A new machine will be representing the RD machine series at the in-house show. This new model is part of the RD 7 series and puts the emphasis on speed. This high-speed machine will be producing a shoe fabric at the in-house show in a gauge of E 22, and will be demonstrating a speed that has never been achieved before.

KARL MAYER’s TM 4 TS-EL is a versatile terry warp knitting machine for processing cotton. In Changzhou, the TM 4 TS-EL, 186″ will be producing a double-face fabric in a gauge of E 28 with fluffy micro-fibres on the outside and absorbent cotton on the inside. Its technology makes this machine an environmentally friendly alternative to looms.

From its range of warp preparation equipment, KARL MAYER will be showing a LONG CHAIN BEAMER (LCB) (Fig. 5) and a BALL WARPER (BW) (Fig. 6) for processing denim, especially for rope dyeing. The efficiency of the LCB may be up to 20 % higher than comparable machines, and the beams are of the highest quality. The BW produces high quality warp balls and guarantees maximum performance. KARL MAYER will also be showing the ISOWARP, a sectional warping machine with an excellent cost:benefit ratio for standard applications. Compared to similar machines on the market, the performance of this machine may be as much as 30 % higher in warp preparation, and weaving efficiency may be up to 3 % higher.

Posted August 23, 2018

Source: KARL MAYER Textilmaschinenfabrik GmbH


Febratex attracts numerous visitors

Since Tuesday, the Febratex fair in Blumenau, Brazil has opened its gates for an expert audience from all over the world. At the traditional textile exhibition, the signs point to upswing. The show has begun successfully with a pleasingly high number of visitors, Mahlo Head of Sales Thomas Höpfl thinks.


He is on site together with Area Sales Manager Miguel Lessel to present the broad Mahlo portfolio of straightening technology as well as process and quality control. With its systems for detecting and correcting warping on line at almost every application, like the Orthopac RVMC-15, the German machine builder is a world market leader. Especially interesting for the Brazilian market, which has established itself as the second largest producers for denim: the weft straighteners are available in special versions for heavy goods with high strain.

“Mr Lessel and I had some interesting talks about current projects”, Höpfl describes the course of the first exhibition day. That indicates a trend that the market is on the rise after several difficult years. For the next few days, the Mahlo team is looking forward to meet more expert visitors and to discuss the latest developments at the textile market.


Mahlo trainees get degree certificate

The first workday of their career is still present in the minds of the five apprentices from Mahlo GmbH. Now, three or three and a half years later, this chapter is already closed. At the end of their successful training, Mahlo CEO Rainer Mestermann handed every junior employee his or her diploma of the Chamber of Industry and Commerce.


“Now it is in your own hand what you will do with your professional future. With your certificate diploma, you have the adequate tool.” Mestermann directed these words to industrial clerks Franziska Berr and Tamara Schäffer as well as Kevin Schumacher, Thomas Thaler and Resul Yaylagül, who can call themselves Electronic technician for industrial engineering, mechatronics engineer and industrial mechanics for machine and system engineering from now on. All of them have happy memories of their apprenticeship and are sure to have chosen the right profession. They emphasize the good working atmosphere. “We were allowed to work self-reliantly but could always ask more experienced colleagues or our trainers for help”, says Berr. With Resul Yaylagül, his joy in his profession and his apprenticing company has transferred to his family: in September, his sister will also start her training as an industrial mechanic at Mahlo. “Of course it is positive for us as a company if family members join us. That means we are doing something right”, so the CEO.
Mahlo generally focuses on training young skilled staff. At the moment, the machine builder is employing 26 apprentices, in September, eleven more entrants start and the application period for next year is already in full swing.

In order to make the apprenticeship not only educational but also enjoyable, trainers Eva-Maria Markl and Andreas Beil frequently come up with special activities. These include for example a bowling event or the introduction days for getting to know each other at the beginning of the apprenticeship.


Mahlo staff completes hydraulic lift training

Safety and responsibility for its staff is written in capital letters at Saal based machine builder Mahlo GmbH + Co. KG. Therefore, employees regularly take part in trainings and further education that are necessary to fulfill their tasks safely. Six colleagues from production and facility management now have completed training for hydraulic lifts in accordance with DGUV.


“That’s like the driver’s license for lifts”, says Jochen Zellner, commissioner for work safety at Mahlo. For an entire day, Biberger Company with its staff member Frank Bernhardt has come to Saal to train the Mahloneses on-site. First, theoretical lessons were on the agenda, for example about safety regulations, equipment technology and the dangers dealing with lifts. The newly acquired knowledge was evaluated in a test afterwards. Then, the participants could put what they had learned into practice. In addition to lifting, lowering, rotating and slewing, they also practiced working safely at the platform as well as driving. “With this training, all participants got the so-called System-Card as a certificate”, so Zellner. The certificate is valid for five years. After that, a short-term training and another test are necessary.



Mahlo GmbH exhibits at ICE Southeast Asia in Bangkok


At the ICE Southeast Asia, held from 5 to 7 September in Bangkok, industry experts can get an overview of the German machine manufacturer Mahlo’s broad portfolio for quality control technology at booth 118 in hall 106. 

“Apart from presenting concepts on how to save money in the demanding coating and converting market, we’ll mainly listen to the challenges that are being brought forward from the visitors of the exhibition”, says Mahlo Area Sales Manager Stephan Kehry. Consulting the customers and advising them for the right process in order to optimize the entire manufacturing setup is one of the major subjects of Mahlo when it comes to customer partnership. The quality control system Qualiscan QMS-12 is just the right tool for this task. With the renowned on-line measurement and control solution, parameters like thickness, basis weight, density, coating add-on and moisture can be determined. The modular system impresses with a broad portfolio of measuring frames in different sizes and sensors for almost every requirement.

“Southeast Asia is on the turning point towards quality oriented products”, Kehry explains. Whilst commodities with low prices were defining the pace of the market in the past, the requirements now have shifted towards a more quality- oriented focus. This paradigm-shift serves two main targets: first, saving cost by creating a higher efficiency and a better transparency. Second, producing an overall better quality to have a better reputation in the market and finally achieving a higher profit. “Both the points can be easily achieved by Mahlo equipment. And on top of that we can share the experience of a family-owned business with a history of more than seven decades.” For an industry that has started to strike a new path, that knowledge can prove to be substantial. A lot of Southeast Asian companies want to enter the European market. To do so, they have to meet the quality standards for this segment. “It’s our aim to help the Southeast Asian customers meeting these standards. It’s our task to make processes more transparent, to provide close loop systems, to avoid mistakes”. According to the expert, it’s those little deviations from the standard or the goal, which make a difference. For the success in the European market as well as for the individual profit.

The ICE Southeast Asia, as the world’s leading paper, film and foil converting industry Exhibition, is the ideal meeting place for exchanging ideas and discussing the best investments. Always up to date, this year’s event will focus strongly on quality, sustainability and on industry 4.0. And Mahlo is providing valid and proven solutions around these topics already today.



Visit us at #FEBRATEX 2018! In only one week from today we will be happy to welcome you at our Stand No 67/68/81/82, sector 1, street 6 in Blumenau, Brasil. One of our highlights will be the presentation of a HKS 3-M. We can’t wait to meet you!

FCEM | Febratex Group is a 100%-Brazilian company known as the main business fair promoter around the country. Throughout its 25 years of existence, the company has become a reference within the national and international markets as the only specialist in business fairs in Brazil focused on development and new technologies for the textile chain.  http://www.fcem.com.br