The next generation of the KARL MAYER Academy

New premises and a new profile for the KARL MAYER Academy in Obertshausen

Progress through training – especially in the warp knitting sector. Alongside its high-tech machinery, KARL MAYER is also offering its global warp knitting customers extensive know-how and expertise to enable them to optimally use the technical possibilities offered by the machines. This company has been running its own training centre for imparting knowledge and know-how for more than 50 years. The KARL MAYER Academy now operates at locations in Germany, China and India, and is extremely successful. Every year, more than 200 students are trained at the headquarters in Obertshausen alone.

The KARL MAYER Academy moved into its modern training centre at its headquarters in April 2019, and the training courses started up in the following May – with a tried-and-tested concept but at a completely new level. “We are now offering our customers courses to qualify them for manufacturing in a digital world, thus giving them the key to success in the future as well,” says Arno Gärtner, the CEO of KARL MAYER. Furthermore, the KARL MAYER Academy, with its bright, open architecture, is a place that will provide inspiration, “Our guests will feel comfortable here and will be able to get to know each other and exchange ideas,” says Arno Gärtner. Learning will become a real experience and a guarantee of the future success of KARL MAYER’s customers.

From left to right: Oliver Mathews, the Vice President Sales and Marekting of the Warp Knitting Business Unit, Arno Gärtner, the CEO, Dr. Helmut Pressl, the CFO, and Christine Wolters, the Head of Corporate Communications at KARL MAYER, at the handover of the new premises to the KARL MAYER Academy

Modern rooms, first-rate equipment, the latest technology and up-to-date knowledge

The KARL MAYER Academy welcomes its guests in Obertshausen in a hall covering an area of 755 m², which offers a bright, learning-friendly atmosphere, modern architecture and technical equipment that has taken a quantum leap forward in terms of quality. Three separate classrooms, equipped with top-of-the-range training equipment, are available for efficiently providing training in small groups.

Specially designed high-tech production machines in the HKS series are available for practical training. “We have invested extensively in the machinery. The more the users understand the possibilities offered by our sophisticated technology, the more benefit they will gain from it,” says Christine Wolters, the Head of the KARL MAYER Academy. The training machines all offer the latest high-tech features, especially with regard to the drive, control and patterning technology. They can also be used to demonstrate the possibilities offered by the digital production of warp-knitted textiles.

The new KARL MAYER Academy also gives an insight into the digital features of KM.ON, and these systems extend the possibilities of increasing the efficiency of the customers’ own production processes. The training machines in the Academy are networked via k.ey – an industry PC combined with the relevant software – and provide access to KM.ON’s secure cloud systems.

Top-of-the range technology for learning and testing covers the entire production process, including warp preparation. A brand-new DS OPTO is used to demonstrate the possibilities of synergistically combining sectional warping used in warp preparation for weaving and direct warping used in warp preparation for warp knitting. This universal, hybrid principle provides maximum flexibility and economic viability when processing beams for warp knitting.

The Academy also profits from being close to the KARL MAYER Development Centre. If there is a demand for market-related courses on special machines equipped with the latest technology, the models in the innovation centre can be used for short-term training.

With its overall concept and equipment, the new premises of the KARL MAYER Academy will provide the know-how and expertise on both the theoretical and practical production of warp-knitted textiles for today and tomorrow. The foundations for additional E-training are also laid here.

Being creative – by exchanging ideas and testing in relation to production

The TEXTILE MAKERSPACE is located very close to the KARL MAYER Academy. The company’s own innovation platform is based on exchanging information and exploiting synergistic effects. It is available to creative pioneers in the textile and new technologies sectors, and provides space for testing, developing and lateral thinking. Its aims are to develop new applications even outside the traditional textile machinery sector, to act as the starting point for new ideas, and to produce the first visualisations of products. “Genuine, new textile applications are generated in an efficient, uniform process in our TEXTILE MAKERSPACE – from the initial thought process to the prototype. This enables product developers to arrive at innovative end-uses much more quickly,” says Michael Kieren, the main initiator of the TEXTILE MAKERSPACE. The proximity to the KARL MAYER Academy ensures that ideas are developed to suit the possibilities offered by industrial production. Fabrics with individual and extremely end-use-specific requirements in terms of yarns, patterns and characteristics can be tested on the production machines used for training, using all the company’s expertise

Michael Kieren and the MAKERSPACE community have already put some new developments in motion. Smart textiles, wearables and 3D printed garments have been the focus of various trade fairs and events for some time now.

Weaving preparation equipment for India from a single supplier

KARL MAYER’s Warp Preparation Business Unit is supporting Rajapalayam Mills Ltd. in the setting-up of a weaving unit

The textile arm of the Indian Ramco Group – part of a US $1 billion group – is an important measure of the national economy and a significant global player. Its turnover is currently in the region of US $183 million, approximately 30% of which is generated by exports. But these results are likely to be surpassed even further. The group is counting on an annual growth rate of 7% to 8% and a doubling of turnover over the next five years. These ambitious plans should be achieved by expanding the associated textile operations. The textile arm of the Ramco Group includes mainly spinning works with a total of about 375,000 spinning units, as well as weaving operations. /1/ These companies focus consistently on high-end products and use high-tech machines to produce them. Textiles for medical applications, woven jacquard fabrics, shirting materials and bedlinen are produced at the Ramco Group’s Ramaraju Surgical Cotton Mills Ltd. The warp beams for these high-quality textile products are processed mainly on KARL MAYER’s direct warpers and sizing machines. This well-known textile machinery manufacturer was also chosen for this latest investment project in the weaving side of the textile business. The company is the sole supplier of a complete production line for weaving preparation to Rajapalayam Mills Ltd.

More vertical production – thanks to its own weaving operations

The expansion project at Rajapalayam Mills Ltd. focused on vertical integration, i.e. the existing spinning activities were to be extended to include weaving operations. The company concentrates on the production of yarns in a finer count range of from Ne 30 to Ne 345 by ring spinning, and from Ne 4 to Ne 24 by open-end spinning. Mainly cotton, Lenzing Modal and Tencel fibres are processed. The production repertoire also includes special processes to produce, for example, flame, core-spun, melange and mercerised yarns. These are aimed primarily at premium products and customised solutions rather than at commodity products. The high-quality, uniform yarns are sent to leading fabric producers in India, in other Asian countries and Europe. Many customers source from external companies if their own capacity is not sufficient. This is where Rajapalayam Mills Ltd. comes in. This company wants to become the preferred suppler of high-quality, yarn-dyed raw fabrics for textile producers with order backlogs. For this reason a yarn-dyed weaving unit with an initial capacity of 10 million metres of fabric per annum was to be set up.

High-tech machines for high-quality products

Rajapalayam Mills Ltd. looked at the technology of various different suppliers for equipping its entire weaving preparation plant. After carrying out intensive investigations, the company chose KARL MAYER. Its expertise in factory planning, strong service organisation, but especially the high-tech machines supplied by this innovative textile machinery manufacturer, were extremely impressive. “Quality is an integral part of the strategy of the Ramco Group. As part of the textile operations, Rajapalayam Mills’ weaving unit is also committed to delivering high-end, customised products. KARL MAYER’s warp preparation machines provide the technical perfection and flexibility that we need,” says N. Mohana Rengan, the Chief Operating Officer of Rajapalayam Mills Ltd.

Complete solution, thanks to a network of subsidiaries

KARL MAYER also scores points in terms of its strategy of clean project execution. Everything was provided by the same company, i.e. from the global subsidiaries in the group: a GIR-O-MATIC® sample warping machine and an ISOMATIC sectional warping machine from the German parent company in Obertshausen, a WARPDIRECT® direct warper with GV creel from KARL MAYER (CHINA) and a PROSIZE® sizing machine for processing spun yarns from KARL MAYER ROTAL in Italy.

Two ISOWARP conventional sectional warping machines, including five warping creels from KARL MAYER India, were also delivered. The machines were the first machines to be fully manufactured in India by the group. Rajapalayam Mills Ltd. was able to profit from its geographical location, since this manufacturer was able to study the features of its new acquisition before delivery. The machines in KARL MAYER’s factory in Ahmedabad were built and made ready for operation for approval by the client.

As well as the company’s sites in India, Germany, China and Italy, KARL MAYER Textilmaschinen AG in Switzerland was also involved in the project. The Swiss marketing experts were responsible for the commercial side of the order. “We are pleased that Rajapalayam Mills Ltd. has put its trust in our company. The order has strengthened our position on the Indian market. Thanks to our established inter-corporate processes, cooperative networks and project management structures, we were able to fully meet all the requirements of the project,” says KARL MAYER’s Senior Sales Manager, Peter Obrist.

The execution of the entire project was also actively supported by A.T.E., the machine manufacturer’s agent in the region.

All the machines are scheduled to go into operation in the second quarter of 2019.

ENVIRONMENT – CLEANER.PRODUCTIONS

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

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)

HIGHER PRODUCTIVITY

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

LOWER ENERGY CONSUMPTION

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

LESS FACTORY SPACE NEEDED

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 

TERRY.ECO

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

KARL MAYER is launching KM.ON – a new brand for delivering digital solutions at a market leader level – and is also showcasing its own software start-up

Conquering the digital world – with KM.ON

On 15 October 2018, KARL MAYER is unveiling its new digital brand at ITMA ASIA + CITME 2018 in Shanghai. KM.ON stands for “digital driven innovation”. This brand brings together the digital solutions portfolio of the KARL MAYER Digital Factory, a new software start-up, and the entire KARL MAYER Group.

KARL MAYER is systematically driving the topic of digitisation forward in order to seize the opportunities offered by the upheavals of our time. “Digitisation is a basic component of our company strategy. With our corporate start-up, the KARL MAYER Digital Factory, we have a software company at our disposal that can act quickly and customer-oriented on the market. Another integral part of KARL MAYER’s digitisation strategy is its participation in ADAMOS, a strategic alliance of German global market leaders in machine construction and the Software AG. On the basis of the ADAMOS technology, and as part of this network for developments, KARL MAYER is living up with the product portfolio of the new KM.ON brand to its claim of being a global market leader also in terms of digital Solutions,“ says KARL MAYER’s Managing Director, Arno Gärtner.

The KARL MAYER Digital Factory is a pioneering company operating alongside this innovative market leader. It employs a team of software specialists and technology experts in a new, creative environment away from the main company headquarters. When speaking about the objectives, Maximilian Kürig who, together with Antonia Gottschalk is one of the managing directors, says, “This new venture should develop efficient digital solutions quickly and flexibly for the benefit of our customers and deliver them under its own, new umbrella brand,” since “Digital solutions are expanding the possibilities of considerably improving the efficiency of our customers’ production processes and giving them unparalleled competitive advantages.”

KM.ON’s digital portfolio of services will support customers in selected areas and is made up of eight solution categories. k.ey – a conventional industry PC together with an appropriate software – provides access to the solutions. The platform of hardware and software can be installed easily and links the machines securely to the protected cloud. This is based on the expertise gained by participating in ADAMOS with regard to the use of an open IIoT environment which is specifically focused on the needs of machinery and plant construction. This enables the benefits of KM.ON to be exploited easily and securely.

 

At ITMA ASIA + CITME 2018, the system, which is made up of eight KM.ON solution categories, together with the first apps and solutions covering the three areas of Management, Maintenance and Service, are being presented.

  • k.management enables the customer 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.
  • The solutions in the k.maintenance category are designed to support customers in their own maintenance operations. As the first solution, KARL MAYER is showcasing the CHECK PARTS app for testing the authenticity of the spare parts, with expanded functions. Above all, the scan-to-order feature is new and makes it even easier to order spare parts online. Automatic data transfer improves the customers’ day-to-day operations when ordering on site, as well as for warehousing.
  • k.service’s product world will, in the long term, include all the functions that manage the communication between the customer and KARL MAYER, should the client require assistance. The ability to make contact quickly, together with efficient communication procedures, guarantees a high level of machine availability. In Shanghai, KARL MAYER is showcasing the latest developments in this system, which is based on the tried-and-tested CONNECT app.

Steps will be taken in the near future to expand the offers of KM.ON. Other solutions and the expansion phases for existing products are already being planned, e.g. in the areas of data analysis, condition monitoring and the digital machine logbook.

 

Textile Makerspace – new online platform for innovative solutions

KARL MAYER launches new website

Since 01.02.2019 the new website www.Textile-Makerspace.com is online. With Textile Makerspace, KARL MAYER presents a platform for innovative, textile applications that have been developed using state-of-the-art technologies – keyword 3D Printing, Smart Textiles, Wearables & Co.

KARL MAYER is stepping up its activities in synergistically linking the textile sector with new technologies, and has launched a new platform, which can be found at www.Textile-Makerspace.com. The aim of TEXTILE MAKERSPACE is to bring together innovations from both areas. In this case, with its specialist expertise and networks, KARL MAYER sees itself as an intermediary and instigator. “The TEXTILE MAKERSPACE should make space for trying things out, for developing, and for innovative thinking – in the textile industry as a whole, but also in other sectors. In this case, the main focus is on exchange and interaction. We want to make contact, exchange knowledge and use synergies – in other words, we want to build our own community,” says Michael Kieren, one of the initiators of TEXTILE MAKERSPACE. The aim is to come up with new developments, some of which have already been set in motion. Smart textiles, wearables and 3D-printed garments have already been at the focus of trade fairs and other events for some time now. KARL MAYER started development work in this field last year with TEXTILE CIRCUIT.

Starting with electrically conductive textiles

TEXTILE CIRCUIT is the first topic to be covered by TEXTILE MAKERSPACE. It demonstrates the possibilities of incorporating electrically conductive yarns into warp-knitted textiles directly on the machine. Functional elements, such as sensors, conductors and coils, can be incorporated very easily, without any additional production steps or compromising the textile characteristics. This has led, for example, to the development of comfortable cuffs for controlling robots and textile charging stations for inductively charging smartphones. Michael Kieren, together with the Product Manager, Sophia Krinner, presented these types of systems for the first time at the specialist IDTechEx Show! in California, USA, in November 2018. The products being shown generated a great deal of interest. Michael Kieren sees a particular potential here for sportswear brands. The TEXTILE CIRCUIT and TEXTILE MAKERSPACE were also the topic of many conversations held at the leading trade fair for the sports sector, ISPO, which was held in February 2019 in Munich.

The next topic – 3D printing

The subject of additive manufacturing is on the agenda for the next stage of the TEXTILE MAKERSPACE platform. The aim is to combine the possibilities offered by 3D printing with textile technology – in order to design and functionalise textiles individually. The impetus for bringing together new and traditional production disciplines at KARL MAYER was a workshop entitled, “Additive Manufacturing for the Textile Industry”. The event was held on 11 January 2018 at the company’s headquarters in Obertshausen. The concept was a great success. Another event will be held on 13 May 2019, the day before the Techtextil exhibition opens. One of the topics will be TEXTILE MAKERSPACE.  Other promotional events for the platform are the next Techtextil fair in Frankfurt, but especially ITMA, which is scheduled to take place from 20 to 26 June 2019 in Barcelona.

Our contact persons for Textile Makerspace:

, Produktentwickler Textiltechnik und 

, Produktentwicklerin Textiltechnik

 

 

Innovations from the textile world for modern life

KARL MAYER will be presenting state-of-the art technology and best-of-textile solutions for warp knitting, warp preparation and technical textiles at ITMA, 20.-26.6.2019 in Barcelona

KARL MAYER will take its visitors on a voyage of discovery through the textile world of tomorrow at ITMA, which is to be held from 20 to 26 June 2019. The meeting-point for all this will be at stand 8.0/B107 on the exhibition site in Barcelona. Here, the visitors can expect a display of highly efficient, complete solutions for production, which will give them the edge over their competitors in the long term. The show includes flexible, trendsetting machines with excellent cost:benefit ratios for use in warp knitting, innovations in warp sampling and direct warping for the warp preparation sector, a completely new machine for composite materials, and new products of the software trendsetter of the industry, KM.ON. The subject of “Future in Textiles” will also showcase well-thought-out textile solutions for modern living and highlight the most important trends of our times – digitisation and sustainability. Innovative warp preparation technology for processing high-quality yarns and a display of exciting fabrics will round off KARL MAYER’s presentation at ITMA.

This innovative show is intended to inspire the sector. “With the innovations that we intend to show at ITMA, we are forging a link from machine building, through applications, textiles and yarns, to the world of digitisation. With our holistic approach, we meet the demands of the upheavals of our time. The nature of production, as well as the use of resources and new technology, and the development of new fabrics and textile materials are all changing radically. These far-reaching changes are throwing up many questions. With the offers of our company, we want to provide our customers with answers and make them confident that their future will be a successful one,” says Arno Gärtner, KARL MAYER’s CEO.

ITM International Textile Machinery Exhibition 2020

 

ITM International Textile Machinery Exhibition

ITM 2020 International Textile, Yarn, Knitting, Weaving, Dyeing, Printing, Finishing and Hosiery Machineries, Sub-Industries and Chemicals Exhibition organized by Tüyap Fairs and Exhibitions Organization Inc & Teknik Fairs Inc. partnership with the Cooperation of TEMSAD (Turkish Textile & Machinery Industrialists Association) will be held at TÜYAP Fair Convention and Congress Center, Istanbul – Turkey. More than 1000 textile technology producer companies are presenting their latest models in operation. ITM is the largest exhibition in Turkey and in the region, is among the most important exhibition in the World.

Facebook: www.facebook.com/ITM2020
Instagram: www.instagram.com/itm2020
Twitter: www.twitter.com/itm2020
Youtube: www.youtube.com/user/ITM2020

 

Guarneri Technology ITMA 2019

ITMA is the trendsetting textile and garment technology platform where the industry converges every four years to explore fresh ideas, effective solutions and collaborative partnerships for business growth. Organised by ITMA Services, the upcoming ITMA will be held from 20 to 26 June 2019 in Barcelona at Fira De Barcelona, Gran Via.
Also this year Guarneri Technology will be present and waiting for you at ITMA 2019. At our booth will live an innovative experience that will immerse you in the world of NIPCO Technology, our unique and patented caleder technology.
We are the solution to your calender needs and demands and we are preparing a lot of surprieses that we can’t wait to share with you at ITMA 2019!
VISIT US AT HALL 2 STAND C211