Integrate to Innovate! – KARL MAYER

The combination of KARL MAYER’s high-tech raschel machines and the software tools of KM.ON set you up for success in our digitized world. First representative is the RSJ 4/1 ON machine with the working width 195 inches.

Fabric development and production need to be perfectly integrated in the textile production value chain. This integration will ensure the time to market and efficiency, required to be competitive in today’s demanding markets.

To meet these innovation challenges, KARL MAYER provides you with the best in class machinery and the best integrated digital solutions.


RSJ fabrics with integrated structure variations – pre-engineered fabrics – have been successfully launched to the outdoor market. Production of pre-engineered fabrics will be perfectly supported by the RSJ 4/1 ON and the integrated digital solutions of KM.ON. Support of the textile development processes is our key to success of our customers. Following find inspirations and textile benefits of pre-engineered fabrics, more detailed information in our Virtual Showroom.


  • Umwelt

Your Benefits Of Engineered Fabrics

Less process steps
Warp knitted fabrics, incorporating complex patterns and zones require less pieces to make an article, leading to less cut and sew, reducing production cost.
Fast development
With less components in an end-product, lead time of design changes will be reduced significantly.
Design freedom
Fashion changes can be translated quickly into new fabric designs. Personalized articles or size variations are imaginable.


RSJ 4/1 ON 195”
The machine is creating 50% more production thanks to the working width 195” while operating at the same production speed as the former model.

Electronic controlled guide bars offer various customer benefits which were reserved for higher value machines before. Electronic guide bar control offers the possibility of producing complex and variable ground structures with long repeats. Pattern data will be provided in the digitized way through KM.ON’s k.ey device.

The RSJ 4/1 ON has got the highest level of integration-maturity for the numerous digital solutions provided by KM.ON to support the progress of the textile value chain.

RSJ fabrics can be applied to a wide range of applications. Beside the mentioned purpose of outerwear, 4-bar RSJ fabrics are well established for swimwear, intimate apparel, lace-like fabrics, spot-nets and tulle constructions.


Increase outputratio of your investment
Earn 37% more output for the same investment compared to former model.
Increase flexibility
Electronically controlled ground guide bars enable immediate changes of ground bar lappings for development work and for regular production.
Pattern Data ON Demand
Pattern data will be provided to the machine through k.ey device for highest flexibility and efficiency in production and development.
Integrate to innovate
The RSJ4/1 ON is the first machine of the KARL MAYER group using the full capabilities of k.innovation to support virtual textile development.



KM.ON’s k.innovation is revolutionizing the product development process in the knitting industry. In the fast-fashion world, innovation cycles are getting shorter and shorter. Our k.innovation solutions support the customers in developing new products and sharing know-how as well as experience.


Using k.production’s state-of-the-art software and digital solutions, the operation of the KARL MAYER machines will be simplified. Sub-processes are digitally supported and improved. An intuitive and mobile logbook and production data acquisition system will be set up, in which tickets can also be created from entries. Thus, “data tags” for the sensor data are generated immediately. enables you to look at the current production process, regardless of location and in real time. The production data are displayed clearly on a dashboard. This simple way of delivering information improves process transparency and acts as a valid database for decision-making and planning. These advantages are based on KARL MAYER’s own system of machine networking.

Learn more about the KM.ON solutions


KARL MAYER is offering a  wide range of RSJ machines with various functions and possibilities. Please use the tables below to find the suitable product for your future success.

Target application RSJ 4/1 ON RSJ 5/1 EL RSJ 5/1 RSJ 4/1
Sport (non elastic) ++ + + +
Outdoor (non elastic) ++ + + +
Outdoor (elastic) ++ + + +
Intimate (ealstic) ++ + + +
Freecut Intimate (elastic) o ++ ++ o
Functional (elastic) ++ ++ + +
Functional zones (elastic) o ++ o o
Factsheet Download Download Download Download

Machine specification RSJ 4/1 ON RSJ 5/1 EL RSJ 5/1 RSJ 4/1
Working width 195 inches 130 inches 130 inches 130 inches
Gauge E28 E28, 32 E28, 32 E28, 32
EL for JBs and GBs
EL long shog 170mm 2 GBs
connectivity KM.ON
Factsheet Download Download Download Download


Bringing progress to our customers with our new HKS 3-M-ON

No disc, more speed – the first three-bar HKS model with electronic guide bar control allows for immediate pattern changes without any mechanical modification and no delay in production.

Thanks to the innovative ON gear, you can easily choose your patterns by connecting your HKS 3-M-ON through k.ey. Instead of waiting for new pattern disks, it is only necessary to select and exchange data. Simply download the required information from a secured cloud to the machine, and you can immediately start to work new articles. In times of rapidly changing market requirements, it is an asset to be able to react quickly on such demands and be able to access to new patterns.

HKS 3-M-ON offers the same performance in terms of speed and design variety as the current version of HKS 3-M with state of the art technology. By using a new main drive system, KARL MAYER minimize your maintenance costs by reducing wear and tear parts.

HKS 3-M-ON can produce a wide range of applications due to its various working width and gauges. It is a perfect combination of efficiency and precision.

Your Benefits


No disc, more speed – HKS 3-M-ON is the fastest Tricot machine with electronic guide bar control.
Immediate pattern change for less stoppage time, higher productivity and quick reaction to market demands.


Minimize your maintenance costs – reducing wear and tear parts.
Less costs compared to pattern discs.
Easy handling – no more mechanical changes required.


HKS 3-M-ON offers the same performance in terms of speed and design variety as the current version of HKS 3-M, but with more flexibility.


Connect to our secured cloud for more innovative KM.ON services to enhance your business and production.

Learn how to easily change and buy new patterns on your HKS 3-M-ON

Sustainable Denim – KARL MAYER

Saving water and chemicals

Environmental protection and sustainability are an important topic. With our new developed technology for indigo dyeing you can save water and up to 50% of chemicals.

Environmental friendly advantages

Chemical and yarn waste reduction

More than 50% saving in the consumption of chemicals to keep the dyeing bath stable. Reduction of the yarn waste thanks to the short yarn pass.

Water saving

The higher fixation of the indigo on the fibre allows a drastically reduced consumption of water in the washing phase.


Stefano Agazzi

Chief of Technology and ProductsKARL MAYER ROTAL S.r.l.

Via Trento No. 11738017 Mezzolombardo / Italy



In­digo dy­e­ing units

KARL MAYER’s future- and customer-oriented dyeing and sizing machine is an efficient tool for the production of uniformly dyed and sized warps for weaving made at the highest econonomical level and produced during an environmentally conscious process. Due to developments in the last years KARL MAYER has been able to implement a consolidated basic technology to provide optimum solutions and resource savings for any application related to the process of indigo dyeing.







KARL MAYER Virtual Showroom 26/07/2019

Metallic curtain fabric produced on our WEFT.FASHION machine. A lurex integrated coarse yarn was added on a transparent ground structure. The ground is very stable in length and width which is distinctive for fabrics produced on WEFT.FASHION. This fabric construction can also be used as an embroidery ground.
For more details visit our Virtual Showroom (link in bio).

 #karlmayer_showroom#KARLMAYER @KARL MAYER Virtual Showroom

La imagen puede contener: exterior, agua y naturaleza


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#FutureOfTextiles – Visit us at booth B107 in hall 8.0! Explore our highlights such as #SustainableDenim, #RevolutionOfBodymapping, #NextToSkin, #YourSuccessInWeaving, #TextileCircuit, #TerryEco, #SolutionsInTechnicalTextiles, #SmartCasualWarpKnits, #SportsAndOutdoor, #ETextiles

Posted by KARL MAYER Virtual Showroom on Monday, June 24, 2019


La imagen puede contener: 6 personas, personas sonriendo, personas de pie y calzado

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La imagen puede contener: una o varias personas y personas de pie

La imagen puede contener: una persona, calzado

La imagen puede contener: una o varias personas

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No hay ninguna descripción de la foto disponible.La imagen puede contener: rayasNo hay ninguna descripción de la foto disponible.La imagen puede contener: 5 personas, personas sonriendo, personas de pie


Exhibitions and trade fairs, specialist lectures, symposia – KARL MAYER 2019 NOV.

Do you want to experience KARL MAYER live at certain events and meet us personally? You will have this opportunity at the following worldwide trade fairs and events. We are looking forward to your visit.


Take a leap into the future – with KARL MAYER ( II )

There was a great deal of visitor interest in the innovations show put on by KARL MAYER at ITMA, held 20.–26.06.2019 in Barcelona

As an innovative market leader, KARL MAYER was presenting its products once again at ITMA, which was held from 20 to 26 June 2019, and its stand soon became the meeting point for the sector. Just under 1,500 visitors with specific issues to talk about were greeted on this modern, inviting stand. On top of these were specialists in search of orientation and people with a general interest. The visitor statistics had a pronounced international flavour. The list of the main countries from which the visitors came was headed by India, followed by Italy, Turkey, the USA, Germany and China.

With its presentation, KARL MAYER had the entire textile value added chain clearly in its sights – from production, through the fabric, to its applications. It was showing innovative machines for warp knitting, warp preparation and technical textiles, solutions for networking machines and the digital world, as well as exciting fabrics and – in an impressive world of experiences – examples of applications with a high market potential. In addition, working responsibly with the environment was an important theme that received a great deal of attention on KARL MAYER’s stand. “We are illustrating the implementation of our key strategic topics of ‘sustainability and the environment’ on various islands at the fair, from energy-efficient machines, through processing yarns with the emphasis on conserving resources, to sustainable warp-knitted textiles and end-use concepts. One of the highlights is undoubtedly our new machine innovation for processing sustainable denim,” the CEO of KARL MAYER, Arno Gärtner, went on to say when speaking at the fair.

Using digitisation systems for warp knitting machines and tapping into new markets

KARL MAYER is combining machine technology with digitisation and this is exactly the right thing to do. “Once again, it became clear from the ITMA fair in Barcelona that the sector is focusing on digital solutions when it comes to process optimisation and customer orientation. That is why we are delighted to receive such excellent feedback on the new systems within our software start-up, KM.ON,” said Arno Gärtner at ITMA.

Two machines with digital features were being premiered in Barcelona. The HKS 3-M-ON can be linked directly to the KM.ON cloud via the k.ey system, which enables the lapping data required to be loaded directly onto the machine.

The RSJ 4/1 ON uses the potential of the KM.ON product group, k.innovation, to optimally support virtual textile development, which is quite usual these days. Therefore, k.innovation delivers much more than just patterning software. “Many of our visitors were particularly impressed by our networked machines and the new possibilities offered by collaborative product development with k.innovation, in conjunction with the RSJ 4/1 ON,” said Oliver Mathews, the Sales Manager of KARL MAYER’s Warp Knitting Business Unit. “The fair went well and we had more than 700 high-quality conversations. We also laid the foundations for many sales contracts and initiated some interesting new projects.” The newly configured RDPJ 6/2 EL also contributed to the excellent feedback, together with its exceptional range of 4D-KNIT products. The textiles produced on this double-bar raschel machine feature a wide range of pronounced, three-dimensional designs on the outer sides, but can also feature openwork patterns, which gives them an advantage over their circular weft-knitted competitors. “News of our new development quickly spread around the fair. Even yarn producers had heard about the 4D-KNIT articles and came to learn more about them on our stand,” says Kay Hilbert. This Head of Product Portfolio Management and his team discussed many promising projects with the visitors. Some of the visitors seemed very keen to invest, and they discussed ideas for new applications.

Ideas and inspiration for using warp-knitted textiles with well-thought-out designs were being demonstrated to the ITMA visitors under the slogan of the “Future of Textiles”. “The applications on show were picking up textile producers, brands and processors from the places where they do business: in the development of new innovations and efficient production,” says Oliver Mathews.

KARL MAYER’s presentation struck gold here.

The “Future of Textiles” area was always surrounded by crowds of people, and many conversations were held on the products being showcased. According to Oliver Mathews, the focus was on the possibilities of substituting woven fabrics with warp-knitted fabrics to minimise costs and environmental loads, and the subject of E-textiles. Extensive development work is being carried out at KARL MAYER into the electrical conductivity of warp-knitted textiles. In the project entitled, TEXTILE CIRCUIT, string bar technology is being used to incorporate electrically conductive yarns directly at any location into the fabric.

The display of applications was also showcasing some exceptional product developments, which are both stylish and functional and can be made-up with little outlay. These include well-thought-out systems for comfortable bras with few seams, a sporty body providing shape and support and made from a new type of power lace, and a swimsuit with a lace look.

An innovative new machine for the composites sector and well-thought-out textile solutions for the construction sector

The new machine, SIM.PLY, proved to be a real magnet for the public in the field of technical textiles. This innovation produces thermoplastic, unidirectional tapes (UD tapes) using fibre spreading technology. Its products – premium tapes with precisely aligned, continuous fibres – are suitable for use in highly stressed, fibre-reinforced, lightweight structures, which are a rapid growth area. The thermoplastic matrix is also easy to process, which makes mass production feasible. The SIM.PLY products feature an impressive, high quality and excellent mechanical properties. The grammages of the spread tape, as well as the impregnated tape, are also uniform, and the fibre volume content is high. The production efficiency is also excellent, thanks to the continuous spreading and impregnating sequences. This line has far exceeded the expectations of KARL MAYER in relation to visitor feedback. “Both our existing customers involved in the lightweight construction, automotive and transport fields, as well as new, interested people from the sports sector, for example, were very interested in this new technology. We had many specific enquiries from our customers at the fair, who were interested in carrying out trials in our Applications Centre in Chemnitz,” says Hagen Lotzmann, the Sales Manager of the Technical Textiles Business Unit.

In addition to talking to partners on the subject of composites, he and his team welcomed all the big clients of KARL MAYER’s established product portfolio. “We had conversations on a wide range of topics, covering our entire technical textiles portfolio – from aviation, through wind power, to geotextiles,” says Hagen Lotzmann. However, he said that there was also a huge interest in building textiles. He and his team had the benefit of the extensive range of products being showcased when talking to the visitors. Examples of their use in textile-reinforced concrete, cheap, flexible and stable roofing materials and bitumen roofing membranes, as well as special plaster grids that increase cracking resistance in the plaster, were all on show. A lightweight, multiaxial construction made from aramid yarns on a COP MAX 5 multiaxial warp knitting machine with an online spreading process for the production of personal protection equipment was also being presented.

Innovative warp preparation technology for a wide range of applications

KARL MAYER’s Warp Preparation Business Unit was presenting new, innovative systems for a wide range of market segments, which appealed to many visitors. Dieter Gager, the Sales Manager of this business unit, and his team recorded just under 430 high-calibre conversations on this subject. After the third day of the fair his conclusion was: “So far, there has been a marked interest in the PROSIZE® and MULTI-MATIC® ranges. Most of our customers came from Turkey and Portugal. The first specific enquiries relating to orders have already been received. The MULTI-MATIC® 32 also attracted many interested people from Italy in particular.”

Italian manufacturers are involved in the high-end fashion market in particular, and know how to appreciate a highly efficient warping machine for producing sample and short production warps. The versatile MULTI-MATIC® 32 requires less time and effort for yarn management and has an impressive cost:benefit ratio.

Other highlights were the new PRODIRECT direct warper, which also has an excellent cost:benefit ratio, and the new LINK-MATIC® system. This innovative system allows for the automatic knotting of the beams within a batch on the PRODYE-S indigo dyeing machine and the PROSIZE® sizing machine when changing the beams within a batch. This enables changeover times to be reduced, productivity to be increased and operator time to be minimised. Also, less yarn waste is produced.

The performance show of the PROWARP® sectional warping machine was being transmitted via a live link from KARL MAYER’s site in Hausen to Barcelona, and was viewed with great interest. This machine operates with the new PROACTIVE Warping system and was demonstrating how this self-learning system can optimise the warp beam quality and consequently weaving efficiency.

KARL MAYER was showing its new GREENDYE technology under the slogan of SUSTAINABLE DENIM. This innovative technical system uses the advantages of indigo dyeing in a nitrogen atmosphere to achieve greater efficiency and sustainability in denim production. This presentation was a real magnet for the visitors. “Our large global key clients from India, Spain and Turkey saw a great deal of promising potential in this new dyeing technology,” said Dieter Gager, the Sales Manager of the Warp Preparation Business Unit. The benefits of the GREENDYE technology soon spread around the fair. Dieter Gager said that, for the first time, customers of our customers – well-known retailers and jeans manufacturers – came to visit KARL MAYER’s stand to gather information on the possibilities of saving resources.

Digital innovations for textile machines

The new KARL MAYER Business Unit, KM.ON, was presenting for the first time at an ITMA in Barcelona, and received extremely positive feedback. “It was a very successful fair for KM.ON. We spoke about many specific projects with a large number of potential and existing customers active in all of KARL MAYER’s business areas,” explained Antonia Gottschalk, the Managing Director of KM.ON GmbH. The visitors were particularly impressed by k.ey, the company’s high-tech connectivity system. In addition to the possibility of networking additional machines, the first bidirectional networking solutions are now available, which permit the seamless transfer of pattern data to the new HKS-3M-ON and RSJ 4/1 ON machines. This enables customers to reduce their time-to-market considerably.

Antonia Gottschalk said that another highlight of the exhibition was the software developed for k.innovation. This game changer in the textile industry combines patterning with collaboration. Design projects involving several participants can be carried out between companies and across different time zones, without changing the system. Any interfaces and disruptions in the system are eliminated by combining the k.innovation and k.ey systems. With k.innovation, projects can be implemented, from the design idea to pattern data transfer, in a continuous workflow. “This system was well received by our own customers, as well as by the big brands, who described it as ‘amazing’,” says Antonia Gottschalk.

Other product categories within the KM.ON brand were also well received by customers in all of KARL MAYER’s business areas, as well as by other players involved in the entire textile value added chain.

KARL MAYER – Sporty, modern lace

Lace articles produced on the multibar jacquard raschel machines developed by KARL MAYER

“Lace – re-imagined” is the title of the lace collection shown on this page. With its graphically inspired patterns, far removed from the conventional floral and decorative motifs, these designs are perfect for creating sporty, stylish altheisurewear fashions. Women always look good in these attractive jumpsuits, whether they are shopping or at the gym. These all-over fabrics were produced on multibar jacquard raschel machines.

The mosaic-like design relies on fresh, multicoloured effects and a wide variety of structures. The ground is made up of different jacquard grounds – ranging from dense to linear hatched effects and open mesh structures – to create an exciting look. Matt/shiny contrasts bring even more dynamism to the design. The inelastic fabric is combined with a functional, stretch warp-knitted fabric produced on an HKS 3-M in a gauge of E 32. The stretch filet fabric containing elastane turns this jumpsuit into an all-round garment that meets every requirement – breathability, comfort and a perfect fit.

The OJ 59/1 B and MJ 59/1 B raschel machines in a gauge of E 24 can be used to produce this mosaic-patterned lace.

The fabric, with its distinct wavy design, is a real in-between fabric. It features dense and transparent zones and thus combines the performance of functional fabrics with the decorative elements of lace.

This special design was created on the MJ 52/1 S. The split jacquard bars of LEISUREE.FASHION machines can operate in the same or opposite directions and form stitches. For example, open powernet structures can be produced between the wavy lines to create a dense effect at this point in the pattern. Elastane, processed by the ground guide bars, guarantees a perfect fit and freedom of movement at the same time. A silvery, grey-blue colour mix emphasises the modern design features of the fabric.

“Clothes maketh the man”

Comfortable, easy-care and stylish – menswear made from warp-knitted fabrics

Warp-knitted textiles with a woven look are conquering the world of men’s fashion. Jackets, trousers and shirts made from these practical fabrics are often mistaken for woven products, but they offer better easy-care and performance properties. Warp-knitted fabrics are crease-resistant and machine washable and they dry quickly. By using clever patterning and selected yarns, they can also be made up into items with comfort stretch, which deliver freedom of movement and a perfect fit.

Just launder and go!

Fabrics for business and casual shirts can be produced on the HKS 3-M high-speed tricot machine in a gauge of E 28. The shirts are non-iron, easy-care and comfortable, and is made from polyester and cotton. Usual an fine polyester yarn is processed by ground guide bar GB 1 to form a tricot lapping and GB 3 produces a 2 x 1 lapping with a thicker polyester yarn. With a partial weft lapping made from cotton in-between, GB 2 is responsible for producing a soft, silky feel.

Warp-knitted textiles for jackets

Also jackets can be manufactured from a fabric produced on an HKS 3-M in a gauge of E 28. In this application the bicomponent Lycra® T400® fibres give the garment a natural look and feel in particular; they improve the crease resistance and provide elasticity and elastic recovery in every direction. The stretch is perfect for producing comfortable jacket fabrics. Textured yarns and the fabric construction also make another contribution to the elasticity. GB 1 works a 2 x 1 lapping and GB 2 works typically a weft lapping to produce the fabric. This construction produces an unusual elastic recovery behaviour for warp-knitted textiles not containing elastane and has already been used successfully to produce tracksuits. However, GB 2 is fully threaded to produce this item of sportswear. On the other hand, the jacket fabrics were produced with a 1 in, 1 out threading arrangement in GB 2, which means they has a slightly structured surface. With a full threading arrangement, GB 3 works a tricot construction as the ground.