JEC Innovative technical systems for the trends in composites

KARL MAYER Technische Textilien looks back on a successful JEC, held 12.-14.03.2019 in Paris

KARL MAYER Technische Textilien GmbH successfully showcased high-tech machines for the composites sector at the JEC composites show, which was held from 12 to 14 March 2019 in Paris. “The mood was upbeat, the number of visitors was high, and I had many in-depth, technical conversations with existing customers and also with people expressing a new interest,” says Jochen Schmidt, the Managing Director of KARL MAYER Technische Textilien GmbH. The many technical discussions held with partners from Europe and the USA, as well as India and China, helped to contribute to the successful outcome. The discussions related to specific projects, plans and trends. According to Jochen Schmidt, a general trend away from simple lightweight construction technology towards components having integrated functions could be detected. The costs of increasing performance by using fibre-reinforced composite materials, especially when using carbon, are only justified for the most demanding applications. This managing director and his team had many conversations with suppliers to niche markets on the possibilities offered by the COP MAX 5. This multiaxial warp knitting machine for processing carbon scores points mainly because of its unbeatable productivity and excellent product quality.

On the other hand, the glass composites sector, with its competitive raw materials prices, continues to gain momentum. The driver of this demand continues to be the wind turbine sector, and increasingly industrial applications as well. A great deal of interest was also being shown in the COP MAX 4, an efficient multiaxial warp knitting machine for processing glass.

Dr. Jürgen Trötzsch, the Section Head of New Technologies at KARL MAYER Technische Textilien, was pleased to report that the sector is increasingly focusing on the topic of thermoplastic materials. He and his team have developed a line for producing thermoplastic UD tapes. They will launch this new innovation at ITMA 2019, but they had already started to arouse people’s curiosity about it at the JEC. “This line was the topic of many conversations. Some visitors came to gather information, while others had specific queries about the machinery, but they were all impressed by the quality of our tapes,” says Dr. Jürgen Trötzsch. This new line is the result of many years of expertise gained by the company in spreading technology. It guarantees a unique, homogeneous distribution of uniform, straight fibres, and thus delivers maximum potential for the lightweight engineering sector.

 

A new player starts in the market for warp preparation machines in India

KARL MAYER, RABATEX INDUSTRIES and A.T.E. set up a joint venture, 29.03.2019

On 29 March 2019 KARL MAYER, RABATEX INDUSTRIES and A.T.E. signed a contract for setting up a joint venture. The legally independent company is called KARL MAYER Textile Machinery India Private Limited, has its registered office in Mumbai and production facility in Ahmedabad.

KARL MAYER is the majority shareholder and takes responsibility for the management of the new company.

KARL MAYER Textile Machinery India Private Limited will focus mainly on the manufacturing and sale of warp preparation machines and creels mainly for Indian market, as well as service and spare parts sale for warp preparation and warp knitting machines.

By means of the newly founded entity, the joint venture partners aim to enhance their position and distribution in the Indian market. Moreover, it is intended to make good use of the existing competencies and synergies, especially in terms of purchasing and customer service.

„With the further development of our international organization, and with our proven way to produce in our main markets, we want to continue to make a contribution to the long-term success of our customers. We are really proud of setting up this joint venture. By pooling our strengths, we will be able to even better support our customers, being close to them in the local market“, explains Arno Gärtner, CEO of KARL MAYER.

Fig. from left to right: Anuj Bhagwati, Managing Director of A.T.E., Arno Gärtner, CEO of KARL MAYER, and Haresh Panchal, Managing Partner of RABATEX INDUSTRIES, during the signing of the contract

„The special contribution of KARL MAYER and RABATEX INDUSTRIES to the joint venture will be production know-how and manufacturing capabilities in the sector of warp preparation machines. Both companies are important players in the warp preparation industry“, says Roland Kohn, President of the Business Unit Warp Preparation of the KARL MAYER Group. KARL MAYER is recognized as a leading and innovative machine manufacturer in the world market in all the areas it is active in.

A.T.E. enriches the group due to its proximity to the market and its strength in customer support. The company has already been KARL MAYER’s distribution partner for many years. „We are honoured to deepen our relationship with KARL MAYER and start a new relationship with RABATEX INDUSTRIES with this new joint venture. We thank our many customers that have encouraged us to take this step with their continuous support. We are confident we will be able to serve them better” says Anuj Bhagwati, Managing Director of A.T.E.

Dr. Pawan Kumar Singh, Managing Director of KARL MAYER Textile Machinery India Private Limited underlines this statement: „We are striving for market leadership in India and supporting the ‘MAKE IN INDIA’ initiative of the Government of India. By combining our know-how and our resources in the field of warp preparation machines, we can provide solutions to our customers with exactly those things which they require for their competitiveness, from production to customer service and support”.

RABATEX INDUSTRIES also relies on the synergies of the new relationship. „ RABATEX INDUSTRIES is excited about this association with KARL MAYER, a technology leader in warp preparation machine industry and A.T.E., India’s leading customer focused textile machinery marketer. Our respective strengths will help us in providing advanced technology machinery backed by professional aftersales service to the Indian textile industry”, said Haresh Panchal, Managing Partner of RABATEX INDUSTRIES.

 

New nonwovens machines extend market opportunities

 

KARL MAYER launches new RACOP-NW series of raschel machines for web bonding

KARL MAYER is setting the standard in the nonwovens sector with its new RACOP-NW machine series. These high-speed raschel machines bond fibrous webs to form nonwovens using two or three guide bars, thus offering all the usual advantages of knitting technology over other processes. This process, therefore, produces textile characteristics, such as elasticity and voluminosity, which is not the case when using chemical bonding agents. Much less energy is consumed compared to thermal processes. The new RACOP-NW models also combine flexibility with maximum productivity – factors that have led to their widespread acceptance by the market.

KARL MAYER sees sales opportunities mainly in reusable shopping bags as an alternative to plastic bags, as well as hygiene products, such as cleaning cloths and hook-and-loop fastenings for babies’ nappies. Technical applications also offer a wide range of end-uses, such as cable sheaths in the automotive sector, filling and insulating materials, e.g. for mattresses, textile surfaces for carpet tiles, and linings and interlinings for shoes and clothing.

Technical concept and market launch

The first models in the RACOP-NW machine series are the RACOP 2-NW and RACOP 3-NW. The machines are available in the gauges of E 12, E 14, E 22 and E 28 and with a working width of 160″ initially. More working widths and optional electronic guide bar control are being planned. The EL function considerably increases the range of patterns and constructions that can be produced, and thus extends the potential of the new raschel machines for use in web bonding. These machines process feed webs and other carrier substrates that can be pierced in thicknesses of up to 5 mm. A device for forming pile loops is optionally available to cater for special applications, and fabrics with special specifications can be produced. As well as being versatile, the RACOP-NW machines are also fast, and operate at a maximum speed of 2,000 min-1.

The first machines have already been sold

The RACOP 2-NW and RACOP 3-NW machines are available to order immediately, and four machines have already been delivered. The new machine series will make its debut at an in-house show to be held at KARL MAYER’s headquarters in Obertshausen during Techtextil 2019, held from 14 to 17 May in Frankfurt.

Techtextil 2019 and In-house Show – KARL MAYER

14 – 17 May 2019 in Frankfurt am Main

KARL MAYER is inviting the sector to an exchange of ideas at Techtextil, stand 3.0/E 18, 14.-17.5.2019 in Frankfurt and to explore the latest RACOP-NW at the In-house Show in Obertshausen.

At the Techtextil 2019 in Frankfurt am Main, KARL MAYER will be demonstrating warp-knitted textiles in Hall 3.0/E 18, with an exceptional level of performance. KARL MAYER is also a trendsetter in the area of ​​digitisation. The manufacturer has grouped all its digital solutions under the KM.ON brand and also presents them at its Techtextil booth.

In addition, KARL MAYER invites to an In-house Show accompanying the fair at its headquarter in Obertshausen. The event is easily accessible by bus transfer and will be premiering a nonwovens machine RACOP-NW.

We are looking forward to your visit!

 

Techtextil In-house Show
14 – 17 May 2019
Messe Frankfurt 
Hall 3.0/E 18
14 – 17 May 2019
KARL MAYER Obertshausen
Development Center

HIGHLIGHTS TECHTEXTIL AND IN-HOUSE SHOW:

  • TEXTILE CIRCUIT

    Electrically conductive textiles are a hot topic at the moment and can be produced in a variety of different ways. The multibar raschel machines can be used to convert electrically conductive textiles with maximum flexibility in terms of geometry, dimensions and location.

  • RAPID TEXTILE – the quick way to new solutions

    The combination of additive production and warp-knitting technology results in functional knitwear using 3D printing. RAPID TEXTILE will be part of the TEXTILE MAKERSPACE, a platform that offers the space to try things out, develop new products and think outside the box.

  • New spacer fabrics with plastic effects

    A new model of a double-bar raschel machine is now enabling completely new designs: warp-knitted textiles with decorative relief surfaces. The designs can be shaped and positioned almost without any restrictions and can also be combined with openwork designs.

  • Weft-inserted warp-knitted textiles for security panels and efficient cut protection

    Burglars frequently use chainsaws and drills during attempted break-ins, but they can be stopped effectively by a new type of patented security panel with weft-inserted warp-knitted textiles in the core. On contact with the cut-resistant textiles, the rotating tools quickly release large amounts of fibres from the material. These become entangled and the tool is stopped. The highly effective security panels are also very light and can be applied very easily to e.g. security doors, armoured vehicles, vaults and cash machines.

  • KM.ON – digital solutions

    KARL MAYER is also a trendsetter in the field of digitisation. This manufacturer has grouped all its digital solutions under the KM.ON brand, and will also be showcasing this system on its stand at the Techtextil.

  • RACOP – Raschel machine for web bonding

    A RACOP-NW, 160″, gauge E 14, is producing a textile for the application area heating textiles at the in-house show. The latest model of the RACOP NW series produces stitch-bonded nonwovens from feed webs and offers a number of technology-related advantages.

    IN-HOUSE SHOW

    During the same time the Techtextil will take place, we will have an In-house Show in Obershausen. At this show a model of the latest RACOP-NW series will be demonstrated. This efficient nonwovens machine produces stitch-bonded nonwovens from feed webs, a technology that offers many advantages.

    Registration In-house Show

    Please choose your preferred day to visit us at the in-house show and register via the following email address:

    Location:

    KARL MAYER Textilmaschinenfabrik GmbH
    Industriestr. 3
    63179 Obertshausen
    maps

    Bus Shuttle

    For all registered vistors, we will offer a daily bus shuttle from Techtextil to KARL MAYER Obertshausen.

    Meeting Point Timetable
    KARL MAYER exhibition booth
    Hall 3.0/E 18
    Daily at 11:00 am
     

Multiple benefit by means of additive manufacturing

Second workshop entitled „Additive manufacturing for the textile industry“ to be held at KARL MAYER, on 13. 05. 2019 in Obertshausen

The combination of new technologies, such as 3D printing, and the traditional textile sector opens up many opportunities for product development. To explore these possibilities is the aim of the workshop called „Additive manufacturing for the textile industry“. The event took place for the first time in January 2018, it was extremely successful and will now be repeated.

The next workshop will take place on 13th May 2019, which is the day before the start of Techtextil in Frankfurt/Main. In its role as host, the cooperation partner KARL MAYER will again make its premises available to the event. The organizer, the Textile Research Institute Thüringen-Vogtland e. V. (TITV), expects roughly 100 guests. Nine speakers from research and practice will highlight the topic of „Additive manufacturing“ in particular. In this respect, the company ViscoTec Pumpen- und Dosiertechnik GmbH will give a lecture on viscous media of the future, Heraeus Noblelight will present IR emitters, and DFKI will provide a contribution on the subject of „Additive manufacturing of modules and housings for electronic components on textile“. Besides, Pedex GmbH will deliver a speech on materials for filaments for FFF-3D printing.

During the programme accompanying the event, KARL MAYER will present the new premises of its Academy. The company’s own qualification site will only move to the new rooms in April 2019. Moreover, the visitors will have the chance to gain first insights into the manufacturer’s TEXTILE MAKERSPACE. An exhibition with offers from industry and research on additive manufacturing will round off this workshop.

More information about the event under https://www.karlmayer.com/de/additive-fertigung-in-der-textilindustrie/.

You can still send your application to Mrs. Siegl under: b.siegl@titv-greiz.de.

Highlights from the universe of high-performance warp knits at Techtextil 2019

KARL MAYER is inviting the sector to an exchange of ideas at Techtextil, stand 3.0/E 18, 14.-17.5.2019 in Frankfurt

KARL MAYER is showcasing warp-knitted textiles having an exceptional level of performance in hall 3.0/E 18 at Techtextil 2019 in Frankfurt. On show will be products with integrated electrical conductivity and shaping characteristics from the new TEXTILE MAKERSPACE platform, an extremely efficient textile solution for protecting buildings, and a completely new generation of warp-knitted spacer textiles. KARL MAYER is also inviting people to attend an in-house show, to be held at the same time as the fair, at its headquarters in nearby Obertshausen. This event is easily accessible by bus transfer and will be premiering a new nonwovens machine for the visitors. KARL MAYER is also a trendsetter in the field of digitisation. This manufacturer has grouped all its digital solutions under the KM.ON brand, and will also be showcasing this system on its stand at the Techtextil.

RAPID TEXTILE– the quick way to new solutions

Textiles with an excellent performance and lower manufacturing costs can be produced by combining the possibilities of additive production with warp knitting technology. Examples of this include warp knits functionalised by 3D printing and these are being presented at Techtextil.

KARL MAYER has grouped together all its activities relating to the use of new technologies and innovative products under the concept of RAPID TEXTILE. They form part of the TEXTILE MAKERSPACE system, a platform that offers the space to try things out, develop new products and think outside the box.

TEXTILE CIRCUIT – the quick way to electrifying designs

Electrically conductive textiles are a hot topic at the moment and can be produced in a variety of different ways. The easiest method is to directly incorporate conductive yarns during fabric production on the machine.

TEXTILE CIRCUIT, another element of TEXTILE MAKERSPACE, shows the potential of warp knitting here. Conductive zones offering maximum flexibility in terms of geometry, dimensions and location can be produced on KARL MAYER’s multibar raschel machines. Examples include inductive charging stations and the remote control of robots, and these are being demonstrated at Techtextil.

New solutions for patterns with plastic effects

Double-bar raschel machines have become firmly established in the production of warp-knitted spacer textiles featuring a variety of designs. A new model is now enabling completely new designs to be produced, i.e. warp-knitted textiles with decorative, relief surfaces. Instead of the spacer layer, three-dimensional design elements are worked on the upper and lower sides. The designs can be shaped and positioned almost without any restrictions, and can be combined with openwork designs. This is opening up a new dimension in near-net-shaped production in particular.

Security panels made from weft-inserted warp-knitted textiles – efficient cut protection for buildings and vehicles

Burglars frequently use chainsaws and drills during attempted break-ins, but they can be stopped effectively by a new type of patented security panel with weft-inserted warp-knitted textiles in the core. On contact with the cut-resistant textiles, the rotating tools quickly release large amounts of fibres from the material. These become entangled and the tool is stopped. The highly effective security panels are also very light and can be applied very easily to e.g. security doors, armoured vehicles, vaults and cash machines.

New raschel machine for web bonding – more opportunities on the nonwovens market

A model in the new RACOP-NW series will be demonstrated at an in-house show in Obertshausen at the same time as Techtextil. This efficient nonwovens machine produces stitch-bonded nonwovens from feed webs, a technology that offers many advantages. This process produces nonwovens having textile characteristics, such as elasticity and voluminosity, which is not the case when using chemical bonding agents. Furthermore, much less energy is consumed compared to thermal processes. In addition to these general advantages, the new RACOP-NW model also offers an exceptional cost:benefit ratio. It is also extremely flexible and can, therefore, be used in a variety of applications. A RACOP-NW, 160″, gauge E 14, is producing a textile for the application area heating textiles at the in-house show.

Seductive velour for the skin

Ultra-soft stretch velour produced on an HKS-3M brings a touch of cosiness to apparel

The supersoft, stretch, high-end velour fabric on this page is setting the trend in the apparel sector. This cuddlesome textile caresses the skin and body. With its gentle drape, it contours the female form with seductive lines, and its attractive shimmer adds a touch of glamour.

It can be used to produce eyecatching evening wear, which emphasising the body, as well as comfortable lounge wear for relaxing on the sofa. The ultra-comfortable pieces range from silky pyjamas, through tracksuits, to bathrobes and under garments, and have also been acceptable attire for the street since 2017. This casual look is in high demand from both men and women alike, especially during the cold months of the year.

Behind this warp-knitted textile, with its high powers of seduction and exceptional wear comfort, is a machine that delivers maximum performance. The fabric was produced on an HKS 3-M, 280″, in E 32 on KARL MAYER’s stand at ITMA ASIA + CITME 2018 in Shanghai. To produce the fabric, ground guide bars, GB 2 and GB 3, worked a counter-notation tricot lapping from polyester, FDY and elastane. GB 1 was also processing polyester. In combination with a textured microfibre yarn as a DTY version, an extra-fluffy surface was produced after raising.

The underlaps made from the microfibre yarns are raised to produce the velour layer – a process that requires experience and know-how. With stretch fabrics in particular, there is a danger that the fabric will tear if the process is not carried out correctly. As long as all the processing stages are managed correctly, a durable, easy-care fabric can be produced. The technology of warp knitting means that the fibres in the pile of the textile have a high pullout resistance, since the pile-forming layer is firmly tied into the ground by stitches. 

KARL MAYER’s textile innovations for the shoe sector

Don’t just stick with what you know – think outside the box

For many years, KARL MAYER has been developing innovative shoe fabrics on its warp knitting machines. A wide variety of textiles, which are setting the trend on the market, can be produced on its high-speed tricot and double-bar raschel machines. The latest developments are aimed at reducing the number of processing steps in the production chain.

Uppers manufactured from a single piece are nothing new. In the sports shoe sector in particular, textile designs, which reproduce the butterfly contours of the entire upper shoe area, are creating quite a stir. KARL MAYER has gone one step further with integrated production. This company uses its double-bar raschel technology to also incorporate the insole directly into the textile product. The covering for the lower area of the shoe is produced during the warp knitting process on an RDJ 5/1 and is joined at the sides with the butterfly shape. A short seam is all that is needed to close the shape of the shoe to which the actual sole is applied directly by injection moulding. This modification to the production process enables making-up costs to be reduced by as much as a third.

But the potential of the double-bar raschel technology is also manifold in terms of design: Different names can be worked to personalise the shoes, as well a different serial numbers and a wide variety of patterns.