Karl Mayer Enables The Automated Production Of Textile Face Masks

OBERTSHAUSEN, Germany — April 20, 2020 — In many places, face masks are now an essential item on the agenda of the compulsory program relating to the exit from the corona lockdown. These masks are required in large quantities, but they are scarce goods. In view of the massive shortage of masks, the textile machinery manufacturer KARL MAYER reacted quickly, and together with partners for production and testing, set up a highly efficient production in record time. One of the used double needle bar raschel machine made by Karl Mayer enables the production of roughly a quarter of a million masks per month.

This innovative company based in Obertshausen initially developed face masks that can be made on Karl Mayer machines in high numbers and in a one-step production cycle. In other words: the masks are produced entirely without the need of any sewing work. Two models are available for the various demands.

Type 1 is produced at short notice and is suitable for everyday life. Due to their 3D shape, these masks have a tight fit and good wearing properties. They offer a convenient air exchange, a soft skin feeling, and prevent friction points on the ears, even after long-term use. The masks can be reused after their utilization. Simply wash and dry them, and the next application can start immediately.

Type 2 provides all the advantages of type 1, but it can be equipped with a replaceable nonwoven lining via a pocket. This increases the filtration capacity, at the same time ensuring minimum waste after use.

Regarding the filtering effect, the certification process is currently underway for a medical standard for both mask types.

To ensure a fast use of the face masks in Germany, Karl Mayer equipped a customer with the required machine technology and the instructions for the production of the masks. The mask manufacture will start at the end of April.

Once the installed Karl Mayer machine is running at full speed, it is possible to produce up to 400 masks per hour or 240,000 pieces per month. At the same time, Karl Mayer is working on reducing the production time for additional machines, so that capacity can be increased as quickly as possible. “By mid-May we can achieve a production of up to half a million masks per month. We are pleased that we can contribute to more safety for people with our know-how and our machines. Further developments, such as mask sizes for children, are in preparation,“ explained Oliver Mathews, sales director of the Warp Knitting Business Unit at Karl Mayer.

Posted April 28, 2020

Source: KARL MAYER Textilmaschinenfabrik GmbH

Warp knitted power jersey for innerwear

Traditional fabric, new production – JERSEY EVOLUTION

Warp Knitting technology is one of the most versatile technologies in textile production. A wide range of machine gauges, yarns, and possible patterns facilitates the production of countless different textiles with special properties.

Typical products from other textile manufacturing technologies can be used and combined with the technological advantages of warp knitted textiles – as demonstrated by the outcome of KARL MAYER’s latest textile product development. Perfectly timed for Interfiliére in January 2020, the innovation department has developed a collection of warp knitted jersey fabrics titled JERSEY EVOLUTION. The production equipment used is the high-performance warp knitting machine HKS 2-S. “With these innovative jersey warp knitted fabrics, we want to open new doors in the world of innerwear, or fabric worn close to the skin,” said Textile Technician Melanie Bergmann. The particular benefits of these new fabrics include a soft, sleek feel that’s fine and smooth to touch, with high elasticity but resistance to permanent loss of shape, as well as smooth, free-cut edges. These characteristics are backed by specially chosen machine configurations and lapping technology: the very good recovery capacity of the bi-elastic fabric is created by implementing a two-needleoverlap. Thanks to a special meshing of the elastane threads, firm and straight edges are created which have a very low or zero tendency to curl. The chosen lapping, together with a high machine gauge, ensure a smooth, fine surface and a flowing fall – or a look and feel customary to circular knit fabrics. But in comparison to circular knit, the manufacturing process of the highly elastic, warp knitted power jersey is substantially more productive. A HKS 2-S boasts the same output as around 2.5 circular knitting machines. This high-performance warp knitting machine also offers advantages with regards to spare parts. The needle leads in warp knitting machines can last up to six times longer than those in circular knitting machines. Thanks to this long usage cycle, costs for a set are halved, which results in running costs being lowered considerably. JERSEY EVOLUTION garnered a lot of attention at Interfiliére with its impressive performance. “We had many conversations with representatives from international lingerie labels. There were also some knitwear manufacturers among them, who wanted to learn more about the technology and its possibilities,” explained Gabriela Schellner, Senior Manager of Textile Technology at KARL MAYER.

Your advantages with warp knitted jersey fabrics

4-Way-Stretch with good recovery
Due to a special lapping construction the fabric receives a very high elongation of up to 245% and has a good recovery.
Free cut with straight edges
Due to the special meshing of the elastane threads, the fabric convinces with cut-resistant edges.
Soft touch
The high gauge in combination with the special lapping gives the fabric a soft and smooth surface with a flowing fall, such as that of circular knitted fabric.

HKS 2-S – The specialist of warp knitted jersey fabrics

Knitting technology is the most versatile technology for textile surface production. Due to a high variation in machine fineness, yarns and patterning possibilities, a multitude of different textiles with special qualities can be produced. The knitting process basically works withouth water or chemicals and is therefore a very environmentally friendly technology.

Your benefits

High productivity
The HKS 2-S is particularly characterised by its high efficiency. One high-performance tricot machine can replace up to 2.5 circular knitting machines.
Low running costs
Needle replacement cycles are approximately 6 times longer compared to circular knitting machines. The costs for one set are 50% less. The running costs compared to cirular knitting machines are therefore highly reduced.

KARL MAYER NEWS ON THE CORONAVIRUS SITUATION

CURRENT UPDATES AND INFORMATION

KARL MAYER monitors the continuously developing Covid-19 virus situation closely and has taken and will take measures focused on the needs of our customers and on the health and wellbeing of our employees and business partners all over the world.

We are there to support you!

Your worldwide contact persons at KARL MAYER remain available via email and phone. Please do not hesitate to contact them. We are still here for you!

Keep up to date

This news page will be updated regularly to keep you informed about the measures taken by KARL MAYER.

NEWS

+++ UPDATE 6 – 04/14/2020 +++

The Indian government has decided that the current nationwide lockdown to control the spread of the coronavirus will be extended until May 3. Accordingly, our factory in Ahmedabad will remain closed until the next review of the restrictions.

As published in our update 4, your contact persons remain available via email and phone. Please do not hesitate to contact them. We are there to support you!

+++ UPDATE 5 – 04/06/2020 +++

The Italian government has decided that for all non-essential industrial activities throughout Italy the shut down will be extended until 13rd of April. This includes also our factory in Mezzolombardo.

As published in our update 3, your contact persons remain available via email and phone. Please do not hesitate to contact them. We are there to support you!
 

+++ UPDATE 4 – 03/31/2020 +++

The Prime Minister of India announced a complete and total shutdown of the country, including a very strict curfew like measures. Until April 14, the population is not allowed to leave their homes except for purchasing groceries, medicines and visit to hospitals. All shops and businesses must remain closed except essential humanitarian services as notified by Government of India. This also applies to our organizations in India.

We have closed the productions until further notice. As recommended by the Indian government, all employees will work from home as best as possible and will continue to be available to customers, business partners and colleagues via telephone and e-mail.

+++ UPDATE 3 – 03/25/2020 +++

Despite the very difficult situation in Italy, KARL MAYER ROTAL remained open and fully operational the last weeks. We have constantly monitored the development of the Covid-19 virus and have taken measures at our Italian site focused on our customer’s needs but more importantly safeguarding the health and well-being of our employees and suppliers.

Production in Mezzolombardo shuts down
The Italian government has now decided to implement even more stringent measures to reduce the spread of the virus. All non-essential industrial activities throughout Italy will shut down starting from 26th of March until 3rd of April. This includes also our factory in Mezzolombardo.

Availability still ensured 
While considering the state of emergency as well as the need to ensure the continuation of all our business activities, the employees of many of KARL MAYER ROTAL’s departments work mobile from home: administration, sales, helpdesk and service, product management as well as design & development.

Your contact persons remain available via email and phone. Please do not hesitate to contact them. We are there to support you!
 

+++ UPDATE 2 – 03/13/2020 +++

Flexible working
For some time now, many employees have had the opportunity to work to a certain extent at locations other than their permanent workplace, i.e. also from home.

Taking into account the increasing restrictions on public life in Europe and the United States (e.g. closure of schools and daycare centers, closure of shops, restriction of public transport, etc.), we have extended these opportunities, especially for employees at the locations affected by this in Germany, Switzerland, Italy and the USA. This allows for a high degree of flexibility to maintain business operations even in these times.
 

+++ UPDATE 1 – 03/09/2020 +++

At the end of January, KARL MAYER started to set up various task forces in its subsidiaries around the world in order to monitor and analyse the rapidly developing situation, first in China and now also worldwide, and to take appropriate action if necessary. 

We are following the recommendations and guidelines issued by the authorities in the respective countries to contain the coronavirus, and have taken appropriate measures to minimize the risk of infection with the virus for our employees and our business partners worldwide.

Use of virtual channels
Restrictions on business travel to and from China have been in effect since the end of January. These are constantly updated in line with the international spread of the coronavirus. In general, business trips to the risk areas defined by the Robert Koch Institute are prohibited. All other business trips are only possible if absolutely necessary for operational reasons in individual cases. All meetings – both internal with colleagues and external with business partners – should, as far as possible, take place via virtual communication channels. 

Production continues
Our plant in China resumed production on February 14, 2020 after successful inspection by the local authorities. Our plants in Italy and Germany also continue their production. As of today, our ability to deliver from our sites on schedule is assured. We are in contact with all partners in our supply chain to be informed about possible effects at an early stage and to be able to react to possible delays.

We are closely monitoring the current situation and will provide information here on possible further measures.

Textile solutions for mouth and nose masks

The coronavirus infection rates are rapidly increasing worldwide, and require readily available solutions.

In this context, the Robert Koch Institute has recently re-evaluated the wearing of mouth protection, including non-certified face masks: “If people – even without symptoms – wear a mask as a precautionary measure, this could reduce the risk of virus transmission to others,” the RKI website states.

With its warp knitting and knitting machines, the KARL MAYER Group offers production technologies for manufacturing textile solutions to contain the spread of pathogens.

YOUR CONTACT PERSON

Gabriela Schellner
Senior Manager Textile Development


Warp knitted face masks – highly efficient production
  • KARL MAYER offers a manufacturing technology for the highly efficient production of mouth and nose masks.

    These masks have been developed at KARL MAYER, and are manufactured during a highly productive one-step production in large quantities.

    In other words: the masks are made in one piece, without the need of any sewing work. Depending on the machine type, an output of up to 400 pieces per hour is possible on a 138″ machine.

KARL MAYER developed various models, for different requirements. We provid some examples of warp knitted face masks in our virtual showroom:

Machines for the highly efficient production of face masks

Quick textile help – provided by KARL MAYER

The coronavirus infection rates are rapidly increasing worldwide, and require readily available solutions. With its raschel machines, KARL MAYER offers a manufacturing technology for the highly efficient production of mouth and nose masks. These masks have been developed at KARL MAYER, and are manufactured during a highly productive one-step production in large quantities. In other words: the masks are made in one piece, without the need of any sewing work. Depending on the machine type, an output of up to 280 pieces per hour is possible. KARL MAYER developed various models, for different requirements.

You can find the relevant examples and contact persons in our Virtual Showroom.

We provide our customers with all the pattern data required for the manufacturing process. The seamless solutions are comfortable to wear and can be reused. The masks had not yet been medically tested and certified, but they can render good services for the protection of fellow human beings. Work is currently being carried out on the further development and certification of these articles.

MORE INFORMATION FOLLOW THE LINK : 

https://www.stoll.com/en/news/stoll-provides-different-patterns-of-oronasal-masks-for-download/

 

Machines for the highly efficient production of face masks

Quick textile help – provided by KARL MAYER

The coronavirus infection rates are rapidly increasing worldwide, and require readily available solutions. With its raschel machines, KARL MAYER offers a manufacturing technology for the highly efficient production of mouth and nose masks. These masks have been developed at KARL MAYER, and are manufactured during a highly productive one-step production in large quantities. In other words: the masks are made in one piece, without the need of any sewing work. Depending on the machine type, an output of up to 280 pieces per hour is possible. KARL MAYER developed various models, for different requirements.

You can find the relevant examples and contact persons in our Virtual Showroom.

We provide our customers with all the pattern data required for the manufacturing process. The seamless solutions are comfortable to wear and can be reused. The masks had not yet been medically tested and certified, but they can render good services for the protection of fellow human beings. Work is currently being carried out on the further development and certification of these articles.

PRODYE installation begins in China

KARL MEYER indigo dyeing machine offers Hingtex yet more variety and quality

The KARL MAYER success story has now reached China, thanks to the PRODYE indigo dyeing machine. The efficient warp preparation equipment for denim production is already a worldwide commercial success, and spring 2020 will see the commissioning of the first machine in China.

The premiere model has been ordered by H.W. Textiles Co., Limited, a wholly-owned subsidiary of Hingtex Holdings Limited. A fully integrated manufacturer based in Hong Kong, Hingtex is one of the world’s most important producers of denim. Key to the company’s success is its continual provision of a product portfolio bursting with quality, variety and uniqueness, particularly since it entered into partnership with Kurabo Industries Ltd. Hingtex’s strategic alliance with the Japanese textiles company was originally established in 2013 as a joint venture. “To differentiate yourself from your competitors, you need to be innovative and proactive, especially in today’s highly competitive and fast changing market,” says Director Stephen Tung.

To ensure that his company can get new developments moving quickly and offer a diverse range of products, the prudent owner has opted for the PRODYE-S from KARL MAYER to expand its warp preparation capacity. The slasher dyeing machine has been configured especially for this application. “PRODYE-S is fitted with a large number of set screws for customising the dyeing process. It allows us to make decisive expansions to our product range and produce items that cannot be copied”, explains Director Stephen Tung. The versatile indigo dyeing machine is suitable for many different kinds of yarn, such as TENCEL™, modal, and core-spun.

PRODYE boasts many additional features that set it apart from the competition. These include a darker indigo shade of up to 5%, lower water consumption and waste yarn, plus double productivity for the production of lightweight denim.

KARL MAYER uses its expertise to help its clients unlock this huge potential.

About Hingtex:

Hingtex was founded in 1981 in Hong Kong, and has been listed on the Main Board of The Stock Exchange of Hong Kong Limited since July 2018 (Hong Kong Stock Code: 1968). The group specialises in the design, manufacturing and sale of denim fabrics for the mid to high-end market segment. Its business activity focuses on the American market; with over 30 clothing brands and more than 120 clients in the USA, Hingtex values its close business relationships. The manufacturer is known for its extensive experience in the production of a wide range of denim fabrics, with the manufacturing of stretch denim blends a particular area of expertise. In addition to this, the group’s clients value its product designs and development capabilities. When it comes to implementing designs, Hingtex relies on sustainable materials. Its production capabilities installed in Zhongshan, Guangdong Province include machines for warp preparation, weaving, dyeing and finishing.

Making day-to-day warp knitting easier

Innovations in spare parts and tools for KARL MAYER machines

KARL MAYER continuously develops not only its machines, but also well thought-out solutions to make operating them simpler and more efficient. In addition, the manufacturer continues to expand its WEBSHOP SPARE PARTS step by step.

Contactor cap for needle bars

One of the latest tools is the Needle Slot Protector, which is a small but highly effective component. It unfolds when the working width deviates from the machine width. As a cap-like element with flat u-profile, the Needle Slot Protector is placed on the needle- free section of the needle bar and fixed with the needle bar cover, which protects the covered section from damage and contamination. The practical cover also contributes to the dimensional stability of the bar. The Needle Slot Protector is one inch wide, is made from lightweight plastic, and is easy to grip thanks to its rough surface. It is currently only available for some HKS models; versions for other series will follow. It is easy to order directly from KARL MAYER’s WEBSHOP SPARE PARTS or by using the k.maintenance app and scan-to-order function.

Segmented 2″ guide unit

Another innovation ensures shorter resetting times with minimum material waste when loading the ground guide bars of warp knitting machines. For fast changeover, 2″ variants are used instead of 1″ guide units, which can be separated into two halves using 1″ segmentation. If a guide needle is defective, it is not necessary to replace the entire unit, as is the case with standard 2″ versions. It is sufficient to simply separate the 1″ part from the damaged area and replace it separately. The practical 2″ plastic guide unit with sophisticated 1″ segmentation was launched at the ITMA 2019 in Barcelona. Since then, customer interest has been growing worldwide. Numerous machines have already been equipped with the new 2″ guide units, and series machines with the units included will be delivered in the near future. There are also plans to expand the fineness variants. The segmented 2″ guide units are available for certain types of guide needles in gauges E 18 to a maximum of E 36.

Extended product range on WEBSHOP SPARE PARTS

KARL MAYER has made its WEBSHOP SPARE PARTS at its headquarters even more attractive, and has therefore expanded its range of spare parts for warp knitting machines – over 6,000 parts can now be ordered directly via the digital ordering portal. The extended selection also includes selected articles for the RACOP and COPCENTRA series machines. The latest webshop upgrade also introduced additional product categories to simplify product searches within the catalogue. For example, under the “Knitting elements” heading, the Tools, Knitting elements and Threading-in comb/Yarn separating comb categories have been added, and the “Mechanical parts” heading has been extended to include the following categories: Bearing, Spring, Joint Rod socket, Knockover plate and Screws/Nuts/Washers.

KARL MAYER buys STOLL – a new strong brand in the KARL MAYER Group

 

 

As part of its growth strategy, the KARL MAYER Group has concluded an agreement to acquire the STOLL Group. The contract was signed on 26 February 2020, and the STOLL Group is to be part of the KARL MAYER Group from 1 July 2020.

By acquiring STOLL, KARL MAYER is opening up additional technological growth potential and an innovative solutions portfolio in the flat knitting sector. STOLL is an international industry leader with approx. 1000 employees and offers innovative tools and services for the knitting of tomorrow.
KARL MAYER is an innovative market leader for solutions in Warp Knitting, Warp Preparation for Weaving and Technical Textiles, with over 2300 employees worldwide.
“The acquisition is an important step in our growth strategy and we are proud to welcome STOLL into our Group. STOLL is an internationally recognised brand in the textile industry and has comprehensive technological expertise and an experienced team in the knitting sector,” explains Arno Gärtner, CEO of the KARL MAYER Group.
With the acquisition, STOLL will become part of the global KARL MAYER Group, an independent family business. As a result, STOLL will benefit from the broad global positioning of KARL MAYER’s sales, service and production sites, and from the opportunities for joint development, such as in the field of digital solutions.
“This alliance brings together two very strong brands in textile machinery building whose solutions portfolios and regional presence complement each other brilliantly. This will enable us to expand and accelerate our innovation strategy in the areas of digitalization and technology, and strengthen our global presence. Our customers will be able to benefit directly from this and increase their competitiveness in the dynamically changing textile industry,” says Andreas Schellhammer, CEO of STOLL.
Both family-owned companies can look back on a long and successful company history, and at the same time prove themselves time and again as trendsetters. In their respective market segments, they represent innovation, quality, long-term orientation, reliability and comprehensive expertise.
The complementary product portfolios and an even greater regional presence in all relevant markets will create new, high-level expertise in the international textile market. KARL MAYER is thus the only company in the textile industry to offer industry-leading solutions for the two main stitch-forming processes: knitting and warp knitting.
The group of companies will thus be even more broadly positioned in the future with the business areas: Warp Knitting, Technical Textiles, Warp Preparation, Flat Knitting and Digital Solutions. Customers can be accompanied beyond the boundaries of technology.
The contract is an asset deal. The well-established STOLL brand will be continued unchanged within the Group. KARL MAYER is therefore not only expanding its portfolio, but is also strengthening its market position with the new brand.
“Our clients were always our focus when preparing the transaction. By becoming part of the KARL MAYER Group, customers will benefit from additional impetus for innovation, particularly with regard to overarching issues such as digitalization. There will be no change to the usual customer support and service,” the CEOs of both companies are keen to emphasize.

 

 

 

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″.