Strong interest in non-nuclear sensors

The Chinaplas lives up to its name as the leading fair for plastics and rubber in the Asian area. The rush of visitors is huge; the halls are full with interested experts and potential clients for the exhibitors. The Mahlo GmbH + Co. KG at booth 5.1 S01 can feel that, too. There, the machine builders’ motivated trade show team presents the Qualiscan QMS system for measuring and controlling important process parameters such as moisture, basis weight and thickness.


“The first day has brought a whole string of promising talks”, Sales Director Thomas Höpfl resumes. Extremely high is the demand for measuring sensors that manage without radioactive emitters. At Chinaplas, Mahlo showcases the Infrascope NIR as well as the Optoscope WLI from its broad sensor portfolio. While the Infrascope NIR uses infrared light to determine basis weight and moisture, the Optoscope WLI works with white light interference in order to measure thickness and coating thickness down to 0,4 µm. “Depending on the application, our clients have way more possibilities with Mahlo”, Höpfl explains. They could get fathom them in a personal interview.

For that, Chinese speaking clients are mostly served by Mahlo’s China Representative Frank Fei and his team. With its representative office in Shanghai, they are the highly competent, local contact point regarding web gauging systems.


The Chinaplas itself is a meeting point for guests from all over the world. “Of course, the majority of visitors at our booth are from China. But we also have welcomed prospects from South East Asia, Israel and the Middle East”, says Höpfl. Now, they are looking forward to the remaining trade show days and more promising interviews.



Mahlo-solutions on display until 17 May

On May 14, the Techtextil in Frankfurt has started its new edition. Until May 17, Mahlo GmbH + Co. KG invites for an exchange of expertise at booth 3.0 B42. On the exhibition space, the newest Mahlo systems for technical textiles await the visitors. They can see the thread and mesh density measurement Famacont PMC-15 as well as a model of weft straightener Orthopac CRVMC-12. With its solutions Mahlo hits the clients’ nerve: high-quality goods due to a more efficient production.

Mahlo Sales Director is therefore pleased with course of the fair so far: “The expert audience at Techtextil is always well-versed in interested in new trends and technical possibilities. We have conducted several intense talks so far.” Now they are looking forward to more successful days.

Visit the Mahlo team at booth 3.0 B42 up until 17 May!



Warp knitted alternatives to save water for an environmentally friendly textile production

CLEANER.PRODUCTIONS are intelligent, end-use applicable concepts as an environmentally friendly alternative to traditional production methods.

Environmental protection is an important topic for KARL MAYER, and sustainable production is becoming increasingly important in textile production and therefore also at our customers as well as all textile producers. That is why our support is made up of efficient machines that score highly in terms of environmental protection through the latest technological innovations.

Our latest environmental contribution CLEANER.PRODUCTIONS stands for zero water pollution compared to other production methods especially water jet looms. This protects sustainable resources while contributing to a cleaner environment. 

Warp knitted fabrics – ecological advantages for production

Warp knitted fabrics score points, not only with regard to their variety, but also in relation to their ecological benefits.


No water pollution during the production process on TM 3 machines, this also means that no of the sizing agent PVA* is drained. (*Polyvinyl alcohol)


This warp knitting machines operate at an impressive level of efficiency – with a speed of 2.000 rpm, the TM 3 has a daily production rate of about 3206 sqm/d – one waterjet weaving machines produces only 12 % of a TM 3


The total energy consumption to produce the same amount of fabric is 2,7 times less than with waterjet weaving.


By using Warp Knitting instead of Waterjet Weaving less than one third of  factory space is needed. This means a 3 times higher GDP value per square meter of factor space (for the same output as with waterjet weaving). It means also less amount of sealed industrial land surface, and less investment cost for purchasing the land!

TRICOT MACHINES – your environmental  friendly alternative compared to water jet loom machines 


Sustainable Production of Terry fabrics. See below how you can save up to 30% of cost with the production of warp knitted terry instead of woven and at the same time contribute in preserving the planet for our children.

KARL MAYER offers a complete range of machines for the production of warp knitted terry fabrics:

  • Warp knitted machines with online brushing
  • Warping machines for filament yarns
  • Warping machines for staple fiber yarns


Mahlo presents its Qualiscan QMS at Chinaplas

One of the leading trade shows for plastics and rubber summons international key players once again. From 21 to 24 May the Mahlo-Team around Chinese representatives Frank Fei welcomes experts from all over the world at booth 5.1 S01.

At the Chinaplas 2019 in Guangzhou plastics and rubber are in the spotlight for four days straight – from raw material over production and converting machinery to coated goods. Over 180 000 visitors gathered information on the latest trends and technologies at last year’s event. This time even more are expected. For a very good reason: the demand for plastic products is steadily increasing. At the same time, sustainability gets more and more important. And that already starts with the production process. Mahlo is up for this challenge with its Qualiscan QMS! “The modular system measures, records and controls critical parameters such as basis weight, moisture or layer thickness over the entire width of the product”, explains Frank Fei.

Visitors at the booth have the chance to examine the Mahlo sensors Infrascope NIR as well as the sensor Optoscope WLI in detail. The first mentioned measures the absorption of infrared energy and can identify basis weight and moisture at the same time. Due to its very high spectral resolution, the sensors can distinguish between components with similar IR absorption. “That allows for a highly selective measuring of a specific component or coat without affecting other components”, says Fei. This way, very thin silicon coatings with 0,3 – 0,5 g/m² can be measured easily and precisely.  

With especially thin coats, where other systems reach their limits, the Optoscope WLI is used. With the help of white-light interference phenomenon, the sensor is able to measure varnish coats down to a thickness of 0.4 µm.

Sound interesting? The Mahlo team happily provides information on individual solutions.


Industry meets at leading fair for textile machinery

The countdown is ticking: when the ITMA show opens its gates on 20 June in Barcelona, the experts of Mahlo GmbH + Co. KG present at booth H2-C203 new systems and solutions for efficient and high-quality textile production and finishing. Three topics are on focus in the machine builder’s appearance.


Via the „Gateway to Industry 4.0“ visitors can immerse in the digital world of Mahlo. mSmart is the name of the concept developed by the technology leader from Bavaria, that defines the digital environment. “Our systems generate data, which the client can use immediately to control on-line. In addition to that, those figures are logged in our new data management system and are retrievable at any time in order to optimize processes and minimize weak points in the production”, Sales Director Thomas Höpfl explains. How measuring data are saved, logged and evaluated, that visitors can test in the mSmart control room. The real-time data of all machines displayed come together here, so every change in a machine can be observed.

The Future of Straightening & Process Control

In the textile industry, the name Mahlo is equivalent to high-end automatic straighteners and process control systems. The experts’ recipe for success is decade-long experience paired with the latest technological developments. Exactly this combination has made Mahlo the world market leader for weft straightening. At the ITMA, the company stays true to its strategy and showcases according to the motto “The Future of Straightening and Process Control” the latest advancements. In live operation, the most recent generations of weft straightener Orthopac RVMC-15 or web gauging system Qualiscan QMS-12, why they enhance every textile production line. Patcontrol PCS-15 for pattern control and Famacont PMC-15 for controlling weft thread and mesh density also contribute to high-quality textile production and finishing. Both are also in live operation at the ITMA. People interested can have the operation principle explained with the help of a demo tower and their own or provided fabric samples at the Mahlo booth.


For especially heavy cases, a separate area is reserved at booth H2-C203: at the Denim-Corner everything revolves around the rugged cotton fabric. The popularity of denim is constantly rising, with no end in sight. Equally increase the end customers’ expectations on design and functionality – and therefore also on the producers. Mahlo introduces in Barcelona a new high-end-solution for straightening the demanding material. “The new technology allows exact and quick controlling even of the heaviest web. In a way unprecedented in the denim industry”, says Höpfl.

A meeting point to connect and establish new contacts will be – just like at previous ITMAs – the Mahlo Bistro. Here, visitors can enjoy Bavarian specialties and recapitulate, how they can improve their production processes. 

Making Quality Of Nonwovens Measurable — Hanwha Advanced Materials Germany Gmbh Utilizes Mahlo Quality Control

SAAL/DONAU, Germany — May 2, 2019 — Hanwha Advanced Materials Germany GmbH has broken new ground with an inhouse nonwoven production facility for its components. In order to optimize the production processes, the manufacturer of high-performance materials uses a quality measuring system from Mahlo.

The headquarters of Hanwha Advanced Materials Germany GmbH is located in the heart of Bavaria, in the Sieben-Täler town of Dietfurt. The manufacturer of high-quality, acoustically effective solutions for automotive engineering belongs to the Korean Hanwha Group, a conglomerate with around 60,000 employees worldwide and a turnover of 55 billion US dollars. The German site currently employs around 250 people who, as Tier 1 suppliers (direct suppliers) for all well-known German automotive manufacturers, primarily produce acoustically effective components such as vehicle underbody panels and textile wheel arch liners. The multilayer structure of the vehicle parts, typical for Hanwha, ensures that noise generated by splash water and road surface is minimised. Up to seven different material layers are required for the desired result. This demands a lot from production.

Own nonwoven fabric ensures top quality

“The particular challenge with textile wheel arch liners is to achieve high acoustic absorption without neglecting robust mechanical requirements,” explains Martin Hering, head of materials development at Hanwha. In order to offer customers maximum quality, Hanwha already wanted to influence the use of materials, Hering continues. Therefore, it was decided to produce its own nonwovens in order to guarantee top quality from the very first fibre. For this project, the Hanwha managers were also looking for a partner who could help make the production processes as reliable and efficient as possible. They came across Mahlo GmbH + Co KG in Saal an der Donau less than 50 kilometres from the company’s site. The traditional company from Lower Bavaria is known for its high-quality systems for measuring and controlling important quality parameters for web materials. With the Qualiscan QMS-12 quality measuring system, Mahlo not only presented the perfect solution for Hanwha – the corporate culture of the two companies also fits together.

Hanwha was founded in 1952 after the Korean War with the ambitious goal of reviving the economy of the battered country. Seven years earlier, the engineer Dr. Heinz Mahlo laid the foundation stone for Mahlo GmbH with his “electrotechnical workshops”. Both companies have continuously developed over the past decades and have written unparalleled success stories. Hanwha has integrated more and more areas into the group and thus developed into a global corporation. The most recent addition was Hanwha Advanced Materials Germany GmbH in 2015. In addition to market leadership in the field of automatic textile straightening systems, Mahlo has also assumed a leading position in process and quality control and expanded this position over the years. The accumulated know-how and experience of the machine manufacturer convinced his partner in this case as well. “The system impresses with its reliability and variability as well as simple operation and integration into the production line,” describes Hering.

In order to reliably meet the requirements of the automotive sector, Hanwha has set itself high standards for the process. This means that very narrow tolerance limits are used in production. In nonwoven production as a preliminary stage for the forming process of textile wheel arch liners, the nonwoven normally consists of a mixture of PP and PET fibres. “Here, in addition to the primary determination of the material mixture and the fibre use, the design of the carding machine and the needling technique influence the final nonwoven product,” explains the head of material development. The possibility of minimizing product fluctuations in the company’s own production helps to achieve low reject rates in the subsequent process steps.

Minimize process fluctuations – optimize lateral profile

Mahlo’s experts have installed a Qualiscan QMS-12 quality measurement system with the Gravimat DFI sensor, tailored to Hanwha’s needs, to determine the basis weight of the nonwoven blend. This allows the supplier to determine whether the longitudinal and transverse profiles of the goods comply with the specifications. “We installed our Webpro M measuring frame at the point in the line after the webs were laid crosswise and continued into the needling machine,” describes Mahlo sales manager Thomas Höpfl. The integrated Gravimat DFI sensor traverses the running web continuously. A multi-channel receiver with double ionization chamber evaluates the incoming measuring radiation and determines the basis weight of the fabric by exact calculation of the measured values. Due to the optimized sensor design, temperature fluctuations in the measuring gap and the position of the web in the measuring gap (pass-line effect) have no influence on the measured value or can be compensated. The recorded measurement data is transmitted via an interface to adapt the incoming profile in the needle machine. Höpfl is certain: “To obtain such a uniform product is only possible with our device. This is because not only is the weight determined in the longitudinal direction, but an even lateral profile is also ensured.”

The results also convince those responsible at Hanwha. “The Mahlo QMS helps to ensure continuous product monitoring in nonwoven production,” says Hering. In this way, one can reliably monitor and control whether the specified basis weight is adhered to. “As a result, the reject rate is consistently at a very low level. But it wasn’t just the machine performance that convinced the global player. “Due to the Korean mentality, Hanwha is not only interested in short-term decisions, but also in long-term planning,” says Hering. Mahlo’s service principle fits the concept perfectly. The service center can be reached 365 days a year. The Team Viewer Tool makes it possible to remotely assess the condition of the Mahlo system, locate errors, update software or perform data backups. This allows problems to be solved quickly and without travel costs. “Thanks to the high degree of in-house production, we can ensure a supply of spare parts well beyond the specified periods,” adds Höpfl.

The high demands that Hanwha places on its own products were also evident in the Mahlo systems. “The system reliably supplies exactly the data that we need to optimize our production processes.” This creates the best conditions for a long-term, successful business relationship.

Posted May 2, 2019

Source: Mahlo GmbH + Co. KG

BON APPETIT! – MAHLO 30.04.2019

Health day at Mahlo on healthy eating

A proper snack satiates, gives energy and on top of that stimulates the memory performance. Unfortunately, there is still too much unhealthy food found on the plates of employees. That is why the Mahlo GmbH has declared “Healthy Eating” as the motto for their second health day.


The machine builder’s staff had the chance to get information on and suggestions for a healthy breakfast at the in-house cafeteria. For that, the experts of Siemens Company Health Insurance Fund (SBK) brought a cereal buffet to Saal. Dried fruits, cereal flakes, seeds and various milk and yogurt types left nothing to be desired – and showed that healthy can also be tasty.


At the cafeteria, the assortment was expanded with whole meal bread and different spreads especially for this day. In addition to that, the organizers had a special idea for lunch: a pumpkin chia seed burger and a Mediterranean turkey rice dish were on the menu. Mahlo’s commercial trainees also made an effort: they served their colleagues home-made cereal bars and vegetable smoothies.    


Just as it was at the first health day with the topic “Back”, the staff’s response was high. Many Mahloneses collected valuable tips from the SBK and gladly took home the prepared recipes for healthy meals. That kind of enthusiasm had to be awarded, of course: in the SBK raffle, Maria Wagner won a fruit basket and Andreas Beil as well as Nina Merschel happily accepted each a cereal box.    

18.04.2019 MAHLO AT CIDPEX 2019

Quality control systems for nonwovens, paper & Co

Whether diapers for babies, make-up remover pads for adults, toilet paper or wet wipes for the household: disposable hygiene articles have become an integral part of our everyday lives. The production of these articles is a science in itself and a major industry. Experts from the sector are meeting at the “China International Disposable Paper Expo” in Wuhan from 17 to 19 April. 30,000 visitors from over 60 countries are expected.

At stand B1L02, interested visitors can see for themselves the versatile measuring and control technology of the German mechanical engineering company. Frank Fei from Mahlo, an expert for quality measuring systems for nonwovens, paper and coating & converting, will advise interested parties on problems in these fields.

The Qualiscan QMS-12 determines important process parameters such as basis weight, moisture or coating application on the running web and thus helps to optimize the production process. Due to the various measuring scanners and sensor variants available, the quality measuring system can be integrated into almost any production line.


New infrared sensor for nonwovens and paper

Fei is proud of the latest addition to its portfolio, the infrared sensor Infralot IMF. The in-house development by Mahlo is available in a reflecting and a transmitting version.  Both versions do not require a rotating filter wheel despite the classic filter measurement principle and thus guarantee a true same-spot measurement of the reference and measurement filter. “This leads to very high accuracy, especially with inhomogeneous products,” explains Fei. The web gauging expert cites moisture measurement and individual component measurement on paper and nonwoven as examples of applications.

With the new sensors, Mahlo is strengthening its position as one of the champions for web gauging technology. “As a global player, we have been putting a lot of development work into applications for a wide variety of industrial sectors for years,” explains Fei. “With the rapidly growing demands of globalized production, quality control will become even more important in the future. Mahlo can provide its customers with the best possible support in this respect.


Straightening technology and process control for an ambitious market

For the third consecutive year now, the Vietnamese market has experienced an upward trend – with rising tendency. The reasons for that are various. The focus, however, is pretty one-sided: quality at attractive costs. This is where process control and straightening technology by Mahlo comes in. With rising success. 

The upswing was also noticeable at the Saigontex trade fair for the textile and garment industry. From 10 -13 April Mahlo presented the latest technology for weft straightening, textile process control and energy saving concepts. “We had our hands full to cope with the rush of visitors. There were many interesting enquiries, especially about sophisticated technology for process control and resource saving,” says Stephan Kehry, Area Sales Manager for Vietnam.

Some say that the boom in the Vietnamese textile industry is related to the current political situation. Some say it is the result of a consistent low-wage policy. As a matter of fact, both are reasons which affecting Vietnam positively. The main reason, however, is the fact that Vietnam can look back on a long textile tradition. 

Of course, one can have goods manufactured in Vietnam to very reasonable prices. To reduce that to the low wages would mean to ignore the facts. Vietnam has done many things right in the past: it has implemented a moderate environmental policy, has never allowed compromises regarding workers’ health or safety and has handled subventions in a future-oriented way. Consequently, numerous companies (mainly from China, Korea and Taiwan) have invested significantly in Vietnam. 


Competitiveness – a growing issue in Vietnam

The resulting upswing is widely visible: international schools, language courses and the desire for western products shape the cityscape. Real estate prices and rents show a similar progressive development as in European metropolises. 

With the rising cost of living, the danger of losing price competitiveness is growing. This is exactly where Mahlo’s program comes in, as Kehry explains: “Specific process control generates control loops that rule out errors and thus rejects or customer demands due to inferior goods. At the same time, processes and overall quality are optimized.”

This increase ensures long-term process reliability and optimizes resource consumption. The result: better quality with lower use of energy and raw materials. This benefits both the finances and the environment. And Vietnam can thus add another chapter to its success story.


Mahlo showcased new developments

Cold as ICE: The international leading trade fair for coating and converting of paper, film, foil and nonwoven held with wintry temperatures true to its name. In the halls of Messe München, however, nobody felt the cold. Responsible for that were the industry’s latest technologies and developments – just like those of Mahlo GmbH + Co. KG.


At booth A5/1510 the nearly 7.200 visitor from 75 countries could witness firsthand the versatile measure and control technology of the Bavarian machine builder. The Qualiscan QMS-12 identifies important process parameters such as basis weight, moisture or coating add-on on the running web and helps to optimize the production process. Due to the various scanners and sensors available, the web gauging system can be integrated in almost every production line. For especially demanding applications Mahlo brought two re-engineered sensors to ICE, as Area Sales Manager Matthias Wulbeck explains: “For a highly precise measurement of transparent coats, our white light interference sensor Optoscope WLI is the right choice. With it, coating add-on as well as thickness can be determined.” The sensor is used inter alia with film extrusion and multilayer films.


According to Wulbeck, Mahlo is especially proud of its latest addition to its portfolio, the infrared sensor Infralot IMF. The in-house development is available in a reflective and transmitting version. Both designs – despite working with classic filter measurement principle – manage without rotating filter wheel and therefore guarantee a true same-spot measurement of reference and measurement filter. “That leads to a very high accuracy, especially with inhomogeneous products”, says Wulbeck. The web gauging expert instances measurement of moisture as well as the single components measurement on paper and nonwoven.

With the new sensors, Mahlo assures its position as one of the leading manufacturers of web gauging technology. “As a global player we have made a strong development in different industrial branches”, Wulbeck concludes. “With the constantly rising demands of a globalized production, quality control will be even more important in the future.”