Innovations – KARL MAYER’s answer to modern-day challenges

KARL MAYER is inviting the textile sector to an in-house show in Changzhou during Shanghaitex 2019

During the Shanghaitex fair, KARL MAYER is inviting its customers and other interested textile companies to see its innovative machine concepts and textile applications at an in-house show. The event will take place from 25 to 28 November 2019 at KARL MAYER (CHINA) in Changzhou.

“We presented our latest innovations to Europe at ITMA 2019 in Barcelona. The feedback from the visitors was excellent. We now want to show textile producers in Asia, who were not able to travel to Barcelona, our ranges that will help them to successfully develop their businesses in the fields of warp knitting, warp preparation and technical textiles,” says Armin Alber, the Sales Director of KARL MAYER (CHINA). This is even more important in view of the fact that the sector is currently rather reluctant to invest because of the economic situation in China in particular, yet it must be ready when the economic conditions pick up. “With our machines and fabric developments, we can offer our customers many advantages on the market over other technologies,” says Armin Alber.

Company building of KARL MAYER (CHINA)

At its in-house show, KARL MAYER will be showing its state-of-the- art machines, including three world firsts. The machines being premiered are a double-bar raschel machine, whose optimised cost:benefit ratio should appeal to shoe fabric producers in particular, a direct warping machine for efficiently processing elastane for the mid-range segment, and a raschel machine, which will put producers of patterned lingerie fabrics in the commodity segment one step ahead of their competitors. Furthermore KARL MAYER will display a three-bar HKS model with electronic guide bar control and integration in the world of KM.ON at the first time in Asia.

Another feature of the show is the latest warp-knitted home and household textiles that offer advantages over woven fabrics. In Changzhou, a modern machine with weft insertion will be producing net curtains featuring the popular woven look. The TERRY.ECO, a concept for the sustainable production of terry goods, and the associated TM 4 TS will also be presented. A textiles and applications show will round off the presentation for the warp knitting sector. This will showcase terry goods in a range of different designs, as well as ultra-fine, smooth lingerie fabrics with integrated, decorative lace at the edges.

KM.ON’s innovative, digital product range will also be presented to demonstrate how these well-thought-out products can give its customers market advantages.

Well-thought-out machine systems for direct warping, sectional warping and sizing in the mid-range segment are also being shown for the warp preparation sector.

The textile innovations and machine developments in the field of technical textiles will appeal mainly to suppliers in the construction sector and producers of interlinings.

Production of tricot fabrics by using electronic guide bar control and digital solutions

As innovation in the field of tricot machines, KARL MAYER will be presenting the new HKS 3-M-ON, 218ʺ, which offers the same performance in terms of speed as the current HKS 3-M with N-pattern drive but with electronic guide bar control. Patterns can be changed quickly by ordering the required lapping from KARL MAYER’s WEBSHOP SPARE PARTS and loading the data from KM.ON cloud directly onto the machine.

Thanks to the electronic guide bar control article can be changed without the previous mechanical handling. The machine can work patterns with repeats of maximal 36  stitches. In doing so no tempi change is necessary. The advantages for the customer: significantly reduced downtimes caused by pattern changes and thereby considerable increased productivity, short response times to changing market requirements and no costs and delays due to delivery times associated with pattern discs.

An efficient way of producing smooth raschel fabrics with lace-like decorative effects for lingerie

KARL MAYER is launching the RJ 5/1, E 32, 130″, a new commodity product line for producing stylish lingerie items. Jan Hippich, a Portfolio Manager at KARL MAYER, is expecting the south Chinese market in particular to invest in this sector. There is a high demand there for lingerie items made from smooth, raschel-knitted fabrics with lace-like decorative bands – marketed under the term, “Seamless”. The making-up costs are also low. The fabrics produced on the RJ 5/1 are made from simple elastane and the type of lapping means that they are resistant to the slippage effect typical of the stretch material. The edges of the fabric do not have to be hemmed, and the consumer is happy with the comfort, since there are just a few seams at the leg and arm openings.

Other advantages of the RJ 5/1 are its exceptional cost:benefit ratio and broad production repertoire. “Basically, conventional products for the RSJ sector can also be produced,” says Jan Hippich.

New developments in the multibar lace sector are also perfect for producing seamless lingerie. A wide variety of yarns can be used for producing different designs using the multibar technology. Fine fabrics produced on an ML 41 in a gauge of E 32 will be presented at the show.

More technology choices for producers of shoe fabrics

The RDJ 6/1 EN is being launched especially for producers of stylish shoe fabrics. This double-bar raschel machine is designed to produce engineered spacer textiles, and delivers a high performance for a reasonable purchase price.

With its optimised cost:benefit ratio, this new machine is intended to bridge the gap between the established models with piezo jacquard technology. Compared to the RDPJ 7/1 EL, the price is more attractive, the speed is higher, and the production repertoire is only slightly smaller. Up to 90 % of the jacquard shoe fabrics currently being manufactured can be produced. More guide bars, EN drive and a well-thought-out yarn feed system to the jacquard bars increase the design possibilities compared to the RDJ 5/1, and enable the patterns to be changed easily.

Net curtains with the look of woven fabrics and the production advantages of warp-knitted fabrics

KARL MAYER has developed magazine weft fabrics with a trendy look for the net curtain sector. One of machines for doing this is being presented at the in-house show. The new WEFT.FASHION TM 3,130″, E 24 produces fine fabrics with a woven look, and uses fancy yarns to create visual effects. Warp knitting is much more efficient than weaving. An expensive and time-consuming sizing process does not have to be carried out, and magazine weft fabrics are extremely slip-resistant.

Warp-knitted terry fabrics trump their woven counterparts

A TM 4 TS, E 24, 186″ is being presented for producing terry goods extremely efficiently. The output of this tried-and-tested tricot machine may be as much as 250% higher than that of comparable air-jet looms, and the energy consumption is approximately 87% lower, since no compressed air is required. Furthermore, no sizing process is needed, which reduces the environmental loads and costs considerably as a result of the sizing chemicals, effluent and energy consumption.

The TM 4 TS is also flexible. It can process staple-fibre and filament yarns to produce a variety of terry goods, including double-face fabrics with an absorbent cotton inner layer and a soft, cosy, outer layer made from microfibre yarns. It can also produce fabrics having different weights.

New machine for the efficient warping of elastane for the mid-range warp knitting sector

The new ISO ELASTIC 42/21 focuses on the requirements of customers operating in the mid-range segment and delivers a high-quality appearance, low space requirements and an excellent cost:benefit ratio. This new machine is particularly interesting for producers of stretch velour fabrics, as well as for modernisation projects.

In terms of its features, speed and flexibility, the ISO ELASTIC 42/21 is very different from the DSE HH 50/32 for the premium market. This new machine concentrates on one type of beam. The finest gauge of the 132″-tricot machine on which the beams are processed, is E 36 or E 24. The price is also aimed at the standard sector. There are no compromises as far as the operation, reliability and product quality are concerned.

Warp preparation technology that meets the requirements of the standard sector

KARL MAYER is presenting the ISODIRECT 1800/800, a direct warping machine with an exceptional cost:benefit ratio for the mid-range segment. This universal machine for processing every type of staple-fibre yarn is exceptionally fast and operates at a maximum warping speed of 1,000 m/min-1. It produces beams having a completely cylindrical structure, precise winding and identical lengths. A computer-controlled measuring system prevents any deviation above 0.15 %. The yarn and beam are also handled very gently by the kick-back function.

An ISOWARP 3600/1250 is also being presented. This manual sectional warping machine is ideal for standard applications in the shirting and sheeting sectors. Compared to similar, commercially available systems, it improves performance in weaving preparation by up to 30% and the efficiency is up to 3% better during weaving itself. A top-quality warp is also produced at every length. Perfect user ergonomics are achieved by equipping the machine with the KAMCOS® 2 system.

The third machine in the group being shown is the CSB Size Box, the key element of the ISOSIZE sizing machine. This innovative machine operates with linearly arranged rollers, a large lowered tank, and filters that are easy to maintain. The yarn is delivered continuously at a constant tension as a bound assembly through the immersion bath. This guarantees maximum sizing quality. Wetting takes place on the basis of a “3 x dipping and 2 x squeezing” process.

An efficient interlining machine and unbeatable solutions for the construction sector

TM WEFT, 247″, E 24 will be demonstrating its features at the in-house show by producing interlining fabrics. This warp knitting machine with weft insertion in line with the stitches operates at an impressive level of stability. At a speed of 1,500 min-1, it is extremely fast and cost-effective. Customers will also be impressed by the functions, user friendliness and reliability of the TM WEFT machine.

Another feature of the show is the topic of textiles for the construction sector. Promising applications for warp-knitted technical textiles include reinforcements for concrete components having a low weight and reduced environmental impact, cost-effective, flexible or rigid roofing materials and bitumen roofing membranes, special plaster grids that increase cracking resistance in the plaster, and self-adhesive tapes for repairing any cracks and holes that do appear.

The WEFTTRONIC® II G is the perfect machine for all these applications. This all-round machine will be presented at the in-house show by means of a video and examples of products. Compared to weaving, it requires less space, manpower and investment in yarns – because it processes rovings. Above all, however, the output of the WEFTTRONIC® II G is unbeatable. When producing a structure for use as a plaster grid in a weight of 140g/m² from glass and polyester in a gauge of E 18, up to 1,000 m² fabric/h can be produced – an increase of 1.670% compared to weaving! In this case, the production costs are 50 % lower and the operator costs are 90% lower. The grids have an exceptionally high tensile strength since, unlike woven fabrics, the weft yarns are processed in a completely straight arrangement.

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