STRONGER TOGETHER, STRONGER THAN EVER

STRONGER TOGETHER, STRONGER THAN EVER

We are living in a time of epochal changes that are imposing essential questions on our way of living, working, and producing: questions that we are all asking ourselves, all over the world, all at the same time.

In fact, it has never been so evident that we are all interdependent: we are increasingly aware of this and we cannot pretend that nothing is happening.

Suddenly everything seems older”, a sensational BMW campaign claimed several years ago .

Suddenly everything has changed”, we’re saying today, and that is why we must reflect on this long and hard, in order to find innovative answers and solutions.

At Tonello we’re asking ourselves in particular what “doing business” is going to look like from now on. We are convinced that we’re facing something that is going to accelerate and reorganize the mental processes that were already in progress and that the most forward-looking companies have already been considering.

Perhaps we have a unique, unrepeatable (hopefully), and precious opportunity: to rethink our job in terms of respect, responsibility, and “reliability”.

Tonello Stronger Together

Reliability is a wonderful word, because it encompasses credibility, loyalty, ethics, as well as reliability.

Reliability, understood as trust, as commitment: it means being there, for ourselves, for the people who work with us, for our customers, collaborators, and suppliers. In short, for everyone we work with.

Being a point of reference means a lot to us, reliable people for others: human to human.

In our opinion, Reliability is a value that derives its importance from knowing how to go beyond simple business, and returning to what the company has always been: an organization that provides for people’s well-being, and their economic, cultural, and social growth.

This is an essential asset for the community and for the territory it operates in.

WE MUST IMAGINE NEW WAYS AND NEW SCENARIOS.

For some time we have already been carrying out an internal process involving and giving value to our people and the time has now come to share this fundamental value with all of you.

Thus we are inaugurating a “Made by People” section of our blog dedicated to our extended family, to everyone, who face the toughest challenges  along with us, with commitment, talent, team spirit, and courage, and with the strength and determination of those who knows they are doing something important and essential: from marketing to production, from administration to “service”, from “sales” to management.

The faces, the stories, the testimonies of our people with become an integral part of our communication because they are Tonello’s “soul”, and day after day they are the ones who literally, “make” the Tonello Brand.

So today we’re happy not to be talking to you about our “machines” (we’ll get back to that subject as soon as possible, obviously), but we’re introducing our “souls” to you: from marketing to production, from administration to “service”, from sales to management.

Tonello Stronger Together

BECAUSE REAL STRENGTH LIES IN PEOPLE.

EVEN MORE UNITED, EVEN THOUGH FAR APART,

WE WILL GO BACK TO LIVING WITH EVEN GREATER PASSION.

COVID-19 Information for Customers and Partners

Mahlo response to COVID-19 

Mahlos Managing Director Rainer Mestermann in the Home office during COVID-19 crisis

Also CEO Rainer Mestermann retreats back into the Home office during COVID-19 crisis, whenever possible.

Dear Valued Business Partners,

These are unprecedented times, with the global spread and the associated impact of the Coronavirus pandemic (COVID-19). Mahlo deeply cares for the safety, health, and wellbeing of its employees and business partners, while continuing to serve our customers.

The proactive steps we have taken over the past weeks were largely ahead of advises from health organizations and governmental guidance. By being proactive, we are working to limit the risk to our team and partners and take care of our customers who we know rely on our ongoing support.

We want to emphasize that as of today Mahlo is continuing its business in all functional areas and we are committed to providing the best service possible to our customers under these challenging circumstances.

 

To continue operations, we have instituted several policies to reduce the risk of potential transmission.

  1. Remote Work
    All employees who can carry out their work remotely are now operating  from their homes. Our team continues to be available by phone, video messaging, and email. Everybody working from home has full electronic access to all resources required to perform their regular duties.We may be working a little differently these days, but never have been more connected.
  2. Travel Restrictions
    We have suspended business travel until further notice. Exceptions are possible and will be handled restrictively considering the specific situation. During this time, our sales and customer service teams will continue to work remotely to service our customers.
  3. Sales & Customer Service, Order Processing, Project Management and Administration
    Our team members in Germany and all subsidiaries can be reached by their regular phone numbers and emails as usual.
  4. Manufacturing Operations
    At this stage, our plant in Germany is fully operational. We have implemented multiple preventive measures, including social distancing, suspending all non-essential vendor visits and increased cleaning measures to ensure the safety and protection of our associates. Visits by customers to our facility are currently not possible. We will continue to accept customer product samples to be sent to our facilities for test.We want to emphasize that for the time being our supply chain works and there are no shortages of any supplies that cannot be managed. Mahlo’s in-house production depth for many components is a specific advantage in these days. Combined with our multiple source strategy this ensures ongoing operation to the benefit of our global customer base.The only area considered as partly critical is freight forwarding due to routing restrictions in some areas. Please be assured that our experienced team will overcome these potential bottlenecks wherever possible.

 

We want to use this opportunity to praise the support and hard work from everybody at Mahlo and our global network of business partners who continue to be instrumental for the running of our business during these challenging times.

Together we will get past this. This is a time of uncertainty and it will take our combined efforts to put this pandemic behind us. Thank you very much for your understanding and continuing support.

We greatly value our partnership.

Plaster grid warp knitted fabric for the billion-Euro market in China

The WEFTTRONIC® II G for glass processing is now taking off in China, too

KARL MAYER Technische Textilien has developed a new warp knitting machine with weft-insertion and thus further differentiated its range offer in this field. The new model, the WEFTTRONIC® II G, is specifically designed to produce light to medium-heavy grid structures.

The stable grid textiles are used as plaster grids and geogrids, as well as carriers for grinding discs – and are produced extremely efficiently on the WEFTTRONIC® II G. Geogrid fabrication is now 60 % more productive compared to the previous version. In addition, less expensive yarns can be processed into high-quality textiles: the textile glass fibre material can cost up to 30 % less than leno fabric production. The machine handles technical yarns extremely gently. Its performance is also impressive. The first WEFTTRONIC® II G was ordered by the Polish manufacturer HALICO in early 2019, followed by orders from China in December. “During our most recent trip to China just before Christmas, we were able to win over two new customers for our company,” said Jan Stahr, Sales Manager of KARL MAYER Technische Textilien. Both companies, Shandong Qiyad and Zibo Glasstex (Shandong Fiberglass), are major players in the industry. After purchasing one machine each, they hinted that they may invest in further WEFTTRONIC® II G models.

An influential family company

Shandong Qiyad is a company privately owned by the Ma family. Mr Ma Xingwang Senior holds shares in two other companies, led by his son and nephew respectively. The companies use around 750 rapier looms in total for their production and thus offer efficiency potential: Depending on product quality, between 13 and 22 rapier looms can be replaced by just one WEFTTRONIC® II G. KARL MAYER Technische Textilien offers intensive service support to ensure a seamless changeover to new technology and to a stateof- the-art machine. The strong partnership led to further recommendations. “During our meetings, the Ma family also introduced us to other potential customers,” says Jan Stahr. The native region of Shandong Qiyad, Shanxian (Shandong Province), is well known for its plaster grid production. Around 5000 rapier looms are in operation here. The companies are all part of an association. Jan Stahr is already in the process of scheduling a pilot system with some of these companies.

A state-owned company with vertically integrated production

The state-run Zibo Glasstex is better known as Shandong Fiberglass. The company has made a name for itself internationally as a manufacturer of glass fibres, rovings and textiles. It is among the top 5 manufacturers of glass fibres in China. The company’s customers in this sector include manufacturers in Eastern Europe who are already operating machines by KARL MAYER Technische Textilien. Following the successful introduction of the technology with the first WEFTTRONIC® II G, Zibo Glasstex plans to invest in further machines. According to the company’s own information, it intends to work a market with an annual volume of 2 billion m² of textile glass fibre material and to achieve a significant market share. Zibo Glasstex therefore intends to invest in further machines in the mid-term.

Flexibility put to the test

In order to gain a better understanding of the possibilities relating to glass grid structure production, the new WEFTTRONIC® II G machine will be available for customer trials at KARL MAYER (CHINA) in Changzhou from June 2020. A wide range of equipment options and patterning possibilities will be available to suit a diverse manufacturing process. The different offers can be tested as part of these processing trials. While working on the machine, customers can get a feel for how the design of the fabric influences its properties and product output, and how this correlation can be used to achieve greater efficiency. If, for example, the square cells of a textile grid are formed with a low warpthread stitch density, the weft threads have a significant freedom of movement within the structure. The fabric is relatively unstable, but is manufactured with a high output. Glass grid manufacturers looking for greater efficiency can use the WEFTTRONIC® II G at KARL MAYER (CHINA) to produce warp knitted fabrics with the same properties as their existing products and thus investigate whether there are any advantages. The performance profiles of the textile products are verified by corresponding laboratory values. Companies with vertically integrated production particularly welcome the opportunity to test the machine out. In addition to textiles, they also produce textile glass fibre materials and can therefore test how their own yarns are processed. The trials are competently supervised by KARL MAYER’s trained technical staff. The WEFTTRONIC® II G is based on a technology unfamiliar to many glass grid manufacturers. During these trials, they can also discover how user-friendly the new machine is.

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.