Rotex Fabrics – risen like a phoenix

Rotex Fabrics (Pty) Ltd is a knitter, dyer and finisher of high quality fabrics for fashion and sports-wear, who believe in establishing meaningful, long-term relationships with customers and suppliers. The purpose built production
facility is situated in the Atlantis industrial area, 50 km north of Cape Town CBD/ South Africa. The company
was incorporated in 1980. Rotex prides themselves in the fact that they are constantly developing new fabrics to
keep up with the ever-changing fashion and technical requirements of their customers. The fabrics are circular
knitted in house, exhaust dyed and then finished in open width. The majority of the fabrics produced contain elastane
with a combination of cotton, viscose, polyester, nylon or acrylic. All cotton/elastane fabrics are bio-polished
using enzymes.

In October 2016 there was an unfortunate fire where the complete dye house and finishing departments were destroyed,
but fortunately nobody was injured. After re-constructing the damaged buildings, the company started
with the installation of the new machinery by the end of April 2017, with the last of the new machines being commissioned
exactly one year to the day after the fire. Three months prior the fire, Rotex started their partnership
with Brückner, and commissioned a new 8-chamber, thermal oil heated stenter to complement the two existing
lines.

The Technical Director, Martin Rohner says: “We were impressed with the new machine, as well as the service
and back-up from Brückner, so much so, that when we had to replace the damaged machines, it was an easy decision
to make, with the result that we installed two identical Brückner stenters. The new investment has enabled
us not only to install the latest technology throughout our dyeing and finishing facility, but also to optimise the
plant layout and grow our capacity to meet our customers’ growing need for high quality, fashion forward, quick response fabrics.”
Regina Brückner, Owner of Brückner Textile Technologies states: “It was really a great pleasure for us to support Rotex as fast as possible after this terrible fire. We admired the energy and the strength of the whole company when they re-built the factory. The cooperation with this special and very expert customer was more than agreeable and we are proud that we could convince Rotex of the quality of our machines and of our service.”


From left to right: Sam Schaffer (CEO and shareholder of Rotex), Regina Brückner (Owner Brückner), Siegfried Rohner (Director and Shareholder of Rotex), Martin Rohner (Technical Director Rotex), Axel Pieper (CTO Brückner)

PLM-IMPIANTI PRODUCCION / EQUIPOS

Textra

Dispositivos de manipulación modulares automáticos que disponen de cintas de transporte y cintas de acumulación para ocupar solamente el lugar de producción necesario establecido por el cliente.

Rotron

Dispositivos de enrollamiento y desenrollamiento y máquinas de inspección y medición que aseguran una mayor cantidad de producto de alta calidad en las fases de producción sucesivas.

Dynapak

Máquinas y sistemas de enrollamiento automáticos para rollos, tejido doblado y tejido doblado de precisión, que garantizan una elevada productividad por medio de un exclusivo sistema patentado que cambia automáticamente el ancho del polietileno según las dimensiones del rollo para embalar. 

Traxell

Sistemas robotizados para la paletización en formas diferentes segun los productos para procesar. 

Parsec

Sistemas informáticos para el registro de los datos de produccion durante los procesos de inspección y embalaje.

Otomax

Dispositivos para la manipulación y el embalaje en contenedores de cartón.

ST. NICHOLAS BRINGS GIFTS FOR MAHLO’S YOUNGEST GENERATION

Festivity is a long-standing tradition with machine builder

Out there, through the woods he comes…, and that already for 47 years. That is how long the St. Nicholas celebration is a tradition at Saal-bases machine builder Mahlo. This year, 17 children of employees were pleased with gifts and treats.

In 1970 St. Nicholas parked his decorated sleigh for the first time in the family company’s cafeteria. Then as now, it was packed with surprises. A bright red bobsled, a cozy scarf and of course sweets were waiting for the little ones this time. To shorten the wait until the arrival of Nicholas, a tasty meal and crafting was on the schedule.
The party was first introduced by company founder Dr. Ing. Heinz Mahlo and his wife Renate, as grandson and owner Ralph Greenwood-Mahlo explains: “It was a special cause for both of them to do something for their employees’ children.” As a young boy, Greenwood-Mahlo participated in the festivities, later he joint in with his own son, then as a guest, never missing a year. “The kids’ shining eyes and the excitement just before St. Nicholas arrives is always special, no matter how old you are.” Many Mahlo-employees whose family members have worked here for a long time might feel the same. They had also stood nervously in front of the holy bishop and recited a song or poem for him. Today, it’s the next generation. “To keep this tradition and strengthen the sense of belonging is a great need for the family”, as Greenwood-Mahlo says.

Casting the part of St. Nicholas is also characterized by permanence. For over four decades, former member of staff Georg Neumayer put on mitre, coat and the long white beard. In 2016 he handed over the crosier to Johann Forstner for reasons of age. Forstner takes his duty as serious as his processor. Every single child got his attention and a few nice words. And the promise that St. Nicholas will be back next year.

KARL MAYER Workshop Vietnam – Starting from November 2017

Workshop Provides 1 Week WKB Course

With 9 months of sufficient preparation, KARL MAYER Workshop Vietnam has officially launched with Grand Opening Ceremony on November 13, 2017.

On the day of opening ceremony, representative from Illies, Kuna Robert and Wu Chun Yan, the Trainers who are providing courses for Vietnam Workshop from KARL MAYER and Eddy Ho, sales manager of KARL MAYER Hong Kong welcomed the participants of the first phase of workshop. The visitors – customers from Hanoi and Ho-Chi-Minh-City – attended the premiere event held from 13 to 17 November 2017, followed from a second one, held from 20 to 24 November 2017. Each of them took place in Ho-Chi-Minh-City and was attended by six participants.

KARL MAYER is devoting to expand the Southeast Asian market, so more and more Vietnamese manufacturers purchase KARL MAYER warp knitting machines. In order to meet the current market demand, KARL MAYER will provide more product-related learning courses to help customers getting familiar with the theory and operation of KARL MAYER machine.

Trainees of KARL MAYER Workshop Vietnam will be attending a 1 week WKB training course, including Machines Theory, Study of warp knitted fabric constructions, Textile calculations and Practical works on training machines. In addition, KARL MAYER Workshop Vietnam will offer additional course of Machine Maintenance Introduction and Article Change. Here introduce some detailed information regarding KARL MAYER Workshop Vietnam:

  • Introduction „Stitch formation“ Warp Knitting
  • Tricot machine structure, technical features
  • Function and explanation of the knitting element movements and their synchronisation with help of chain links
  • Explanation of the KAMCOS in details and hands on practice of each participant.

A high-fashion look for upholstery fabrics produced on the new RASCHELTRONIC®

The fabric makes a sofa

Since the emergence of the athleisure trend, it has become clear that various synergies existing between specific segments of the textile sector can be exploited. For example, lingerie lace is being incorporated into the shirts of women runners, and functional materials are being used in sexy briefs. Home and household textiles can also profit from the transfer of ideas from one sector to another. For example, the possibilities offered by typical warp knitting machines used in the clothing sector are now bringing a touch of flamboyance to the home.

KARL MAYER has taken up this trend of transferring ideas from one sector to another in the textile industry and has used its tried-and-tested RASCHELTRONIC® machine to produce stable upholstery fabrics. This high-speed jacquard raschel machine has been a firm favourite among producers of sportswear and lingerie fabrics for some time now. These companies are using the RASCHELTRONIC® to produce stretch and non-stretch textiles with functional zones. The model used is designated the RSJC 5/1 EL, and this new collection has made it an interesting proposition for manufacturers of home textiles as well. The fabrics feature an attractive, graphic design with open-work constructions, and are extremely heavy for RASCHELTRONIC® fabrics. The final fabrics weigh between 330 and 400 g/m², depending on the arrangement of the weft lapping. In some designs, the weft runs along the holes, which therefore remain open, and does not join any stitch wales. In other patterns, the ground bars with the weft add to the openings, which affects the appearance and characteristics of the textile. The warp-knitted textiles, with the partially filled-in openings, are denser and more stable in every direction. All the fabrics also have the appropriate abrasion resistance values for use as upholstery fabrics. The results of abrasion tests carried out by textile developers at KARL MAYER lie within the average range of the specific requirements of most manufacturers. The performance of these durable warp-knitted fabrics has also attracted the attention of shoe fabric producers. “The machines are selling very well globally,” says Stefan Gross from the Product Development, Textile Technology Department at KARL MAYER.

Further reasons for the success of the RASCHELTRONIC® include its high level of flexibility, since the EL feature enables different patterns to be worked easily one after the other at an exceptional production rate. At a maximum speed of 1,000 min-1, this new high-speed jacquard raschel machine can produce an average of 48 metres of this new upholstery fabric per hour. The machine gauge is E 18 and the working width is 130″. Textured, tanglelaced polyester is used as the yarn.

 

KARL MAYER SECTIONAL WARP – NEWS

Using large sectional warp beams to produce warp-knitted cotton terry towels efficiently

KARL MAYER develops and manufactures high-performance warp preparation machines for both weaving and warp knitting and, in order to do this, uses the synergies that exist between the two sectors. The WKD-SP is the latest result of this know-how and technology transfer. This direct warping machine is based on the WARPDIRECT® machine for the weaving sector, and processes staple-fibre yarns. Producers of warp-knitted, cotton terry towels should find this particularly interesting. This new machine delivers all the performance features of its predecessor but, above all, its advantages can be exploited by using back beams, with their wider widths, as sectional warp beams (SWBs) in the warp knitting sector.

Efficient warping with the WARPDIRECT®

Die WARPDIRECT® is a universal direct warping machine for processing every type of staple-fibre yarn. It produces high-quality beams for the slasher dyeing process in denim dyeing, for combining all the yarns on the warp beams on the assembling machine, and for processing in a sizing machine with subsequent warp beam production. The back beams for these various processes are of the highest quality. The beams are completely cylindrical, thanks to an intelligent press roller system and optimum yarn laying, and the yarns are arranged extremely accurately. A computer-controlled length measuring system delivers a length accuracy of 0.1 %. The yarns are also handled very gently. Other advantages of the WARPDIRECT® include its low maintenance costs and high productivity. The maximum warping speed is 1,200 m/min. The easy-to-use, graphic touchscreen guarantees optimum machine usage. All these advantages enable the WKD-SP to now be used for the production of SWBs for the warp knitting sector as well.

Efficient production of towels using the WKD-SP and TM 4 TS EL

The starting point for modifying the WARPDIRECT® to create the WKD-SP were the demands made by the TM 4 TS EL during use. An efficient direct warping machine was needed to match this efficient machine for producing warp-knitted cotton terry towels. The modifications that were needed relate mainly to the software. The program changes enable constant yarn tension levels and completely uniform SWB circumferences to be produced. SWBs with the same circumferences and yarn tension levels are needed, since several of them are processed at the same time on the TM 4 TS EL.

The SWBs of the new direct warping machine have the same width as back beams. This means that the number can be reduced when loading the machine, and the direct beaming process becomes more efficient. For example, with a TM 4 TS EL with a gauge of E 24, a working width of 186″ and the normal threading arrangement of 1 in, 1 out, eight SWBs per axle of the beam frame can be reduced to two large-format ones.

KARL MAYER is putting the emphasis on flexibility by concentrating specifically on the width of the SWBs. For example, the extra-wide SWBs can also be used on its tried-and-tested direct warping machine and, for the WKD-SP, this manufacturer enables back beams to be processed to suit customer requirements. Customers are, therefore, able to use beams supplied by both local and global suppliers.

When a vision becomes reality – BRUCKNER

 

CDL KNITS / TROPIC KNITS in Mauritius strike a new path in textile finishing

The TROPIC KNITS Group located in Mauritius is with 3.000 employees one of the biggest producers of high-quality fine knit garments in the Indian Ocean. Well-known international brands from Europe, U.S. and South Africa are among the company’s most important customers since many years.

Pic 1: Main entrance at TROPIC KNITS

The textile industry has changed very much particularly in the past years, not least caused by a changed consumer behavior: increased online shopping, shorter production lead-times, fast fashion cycles and quick turnaround for new collections coupled with high quality customer demands at the right price.
And, in addition to that, the focus has been on sustainable production meaning compliance to environmental standards and social compliance. These are the great challenges for TROPIC KNITS, the garment division of the Group. The company achieves this among other things thanks to their excellent targetoriented, customer focused and flexible team. CDL KNITS, a fully integrated knitting, dyeing and finishing plant is the Fabric Mill division of the TROPIC KNITS Group. There, they have the ability to control the complete production chain which allows rapid optimization of processes to improve fabric quality as per customer demand.
At Forest Side in Mauritius, CDL KNITS is producing every day approximately 17 tons of knitted fabric out of which 80% is assigned for TROPIC KNITS which converts them into garments. The rest is exported to South Africa in open-width fabric form.

Since quite a long time the operations and finishing team of CDL KNITS has been looking for leaner production processes that would lead to further savings in terms of resources and energy for the company.
During ITMA 2015 in Milan the first ideas were discussed with different textile machine manufacturers and very soon their thoughts became a mature and solid concept. CDL KNITS manufactures a variety of cotton fabric, cotton blends and viscose. The finishing line they operated at that time comprised a relaxation dryer, a stenter and a compactor. The intention was to replace these three finishing machines by only one line without compromises regarding quality. In the beginning this seemed to be rather unrealistic on a technical point of view.
The German textile machinery producer BRÜCKNER TEXTILE TECHNOLOGIES kept their ears open to the concept. An intense exchange of insights began, new ideas were discussed and several fabric trials were performed in the BRÜCKNER Technology Centre in Leonberg/Germany. Together, a completely new machine concept has been developed which CDL bought for their production site in Mauritius. Most important was the mutual trust which has developed during the phase of conceptual design between BRÜCKNER and CDL KNITS. The excellent assistance by the complete BRÜCKNER team, the technological advice and the positive results of the trials in Leonberg were in the end convincing and crucial for the purchase decision.
The new BRÜCKNER line for knitted fabric which will in future replace CDL’s three finishing machines is a special design: a relaxation dryer with pre-arranged stentering zone. Scroll rollers in the entry of the line provide for the spreading of the fabric and skew straightening rollers for the reduction of spirality.
After that the fabric is pinned on precisely directly behind a special selvedge spreading unit, so that the selvedge waste is later reduced to a minimum. A non-lub vertical transport chain, developed particularly for knitted fabric, transports the fabric through a ten-meter-long stentering zone. It is provided with a selvedge gumming unit, comprising several IR dryers and further hot air dryers for a complete drying of
the gummed selvedges. Depending on the process and the fabric quality it is possible to operate with up to 60% overfeed and a wet overstretching of 40% and more.

Pic 2: New BRÜCKNER line for knitted fabric at CDL KNITS, Mauritius

At the end of the stentering zone a selvedge cutting device is installed. With minimum tension the fabric is then fed on to a specially coated transport belt leading into the 4-zone relaxation dryer. The fabric is dried with an optimized air control concept and it is relaxed due to the tumble-like movement so that the residual shrinkage is reduced to a minimum. The individually adjustable air flow in the dryer and the wet spreading and shrinkage in the stentering zone allows to influence the quality features such as shrinkage, fabric width and fabric surface to the optimum. The curling of edges in the dryer is prevented by a systematic and selective arrangement of the circulating air. This new technology allows to save previously required expensive process steps.

Pic 3: View of the stentering zone in front of the relaxation dryer

BRÜCKNER’s Technical Director for Mechanical Design, who is an expert for the finishing of knitted fabric at the same time, wanted to assure himself that the recently developed concept is performing perfectly.
He visited CDL KNITS in Mauritius directly after commissioning of the new line. Together with the customer he made tests with different fabrics and determined the optimum process parameters for each fabric quality. The operators were directly involved and correspondingly trained.
After a short time CDL could start the production and the results speak for themselves. The fabric quality is better than expected and the residual shrinkage as well as the spirality are for all fabric types less than 5%. CDL is already now saving about 40% of electrical and thermal energy compared to their previous process. But the biggest saving is definitely the significant reduced process time. Where previously 90 hours were required, is today 20 hours to achieve the same productivity. This gives enormous benefits regarding the delivery time.

Pic 4: 4-zone relaxation dryer in the new line for knitted fabric of CDL KNITS

But there are some more aspects which made CDL KNITS invest in a BRÜCKNER line. The state-of-the-art lines of the German machinery producer are very robust and durable. Spare parts and support are available for all machines, even if they are 20 or 30 years old. In addition the machines are produced 100% in BRÜCKNER’s own plant in Tittmoning / Bavaria, in Germany and they are always tailor-made to the
customer’s needs. Furthermore BRÜCKNER attaches particular importance on an energy-efficient technology to save costs for their customers when operating the lines and to reduce simultaneously the consumption of resources.

The TROPIC KNITS Group is part of the FINE KNITS cluster of CIEL TEXTILES which is also located in Mauritius.
The complete Group has more than 20.000 employees with an annual turnover of about 300 million USD. Once a year CIEL TEXTILES hosts the CIEL Textile Chairman’s Manufacturing Excellence Award for its capital intensive companies. This is a good occasion to bring together the employees of the individual business units and to emphasize the team spirit and the solidarity of the whole team. Because
only together it is possible to master challenges. The Knitting Division of CDL KNITS won the award for Manufacturing Excellence twice in 2015 and 2016. This year, in September 2017, CDL won the World Class Innovation & Creativity Award. The installation of the new BRÜCKNER line at CDL KNITS and the corresponding benefits for the company played a small but nevertheless important role in winning the award.
The group and each individual business unit attach great importance on sustainability. This includes the saving of resources (water, oil, electricity, etc.), but also social responsibility with a vision for the future.
CDL KNITS came up with the initiative “Stairway to Hope”. The objective is to help underprivileged people in the community. Selvedge waste from production is provided to socially disadvantaged persons who knit these into rug mats which they sell and earn a living. The required equipment (for example wooden frames or needles) is made available by CDL KNITS who also supports the people in the sales of their products. The project is also known as “WASTE to GOLD”. Since last year, CDL KNITS is engaged on a yearly basis on a D-Day, also known as Love Day, with a community close to its production facility. This is an opportunity where all the employees of the company would gel with the people living in the community 

and organise different activities such as free medical check-ups, planting of trees, cleaning of the environment, awareness on drugs and diseases and also distribute food and school materials to the needy. In September 2017, CDL KNITS was also awarded the CSR (Corporate Social Responsibility) Award among the capital intensive units of CIEL TEXTILES.

Verena Ruckh, Head of Marketing at BRÜCKNER, is really inspired. „A great commitment with many exciting social projects. During my stay at CDL and TROPIC KNITS in Mauritius I met so many highly motivated people from various cultures who always welcomed me with a smile. When I walked through the company I could feel the spirit of willing to move something forward together as a team. This is something
very special and it impressed me deeply. Keep it up!”
The Group now benefits from a state-of-the-art and durable BRÜCKNER line for knitted fabric which clearly saves thermal and electrical energy and streamlines their internal processes. Improved fabric quality and shorter lead-times are other benefits derived from the new finishing line. This allows TROPIC KNITS to offer in future the highest possible quality and to position itself as a very good alternative to suppliers from China and the Far East.

Additive Fertigung in der Textilindustrie

TITV-Workshop am 11.01.2018 bei KARL MAYER

Die Textilindustrie ist eine der Vorreiterbranchen bei der Nutzung neuer Technologien und innovativer Produkte. Auch die Additive Fertigung hat sie bereits für sich entdeckt, beispielsweise zur individuellen Gestaltung und Funktionalisierung von Textilien per 3D-Druck.

Welche Verfahren stehen zur Verfügung? Welche Ergebnisse werden dabei erzielt? Wer sind wichtige Anbieter und Erfahrungsträger? Im Workshop ADDITIVE FERTIGUNG IN DER TEXTILINDUSTRIE liefern das TITV und wir Antworten zu diesen und weiteren Fragen. >> JETZT BEIM TITV ANMELDEN

Anmeldeschluss ist der 21. Dezember 2017.

EVENT INFORMATIONEN

Veranstaltungszeiten

 

Donnerstag, 11. Januar 2018

ganztägig

Veranstalter

 

 

TITV Greiz

Textilforschungsinstitut Thüringen-Vogtland e.V.
Zeulenrodaer Str. 42
07973 Greiz

Veranstaltungsort

 

 

 

KARL MAYER – Obertshausen

KARL MAYER Textilmaschinenfabrik GmbH
Entwicklungszentrum
Industriestraße 3
63179 Obertshausen
ROUTE BERECHNEN

Teilnahmegebühr
  • Teilnehmer – 190,00 € zzgl. USt.
  • Start-ups – 50,00 € zzgl. USt.
  • Aussteller – 250,00 € zzgl. USt.

REFERENTEN

Kai Kegelmann

Geschäftsführer

Kegelmann Manufacturing GmbH & Co. KG

Prof. Dr. Dr. Andrea Ehrmann

Fachhochschule Bielefeld

Fachbereich Ingenieurwissenschaften und Mathematik

Vortrag: „3D-Druck auf Textil – Herausforderungen und Chancen“

Antonia Gottschalk

Leiterin Digitalisierung

Karl Mayer Textilmaschinenfabrik

Dr.-Ing.  Martin Schilling

Geschäftsführer

3D-Schilling GmbH, Sondershausen

Vortrag: „Sind textile Inserts in der additiven Fertigung Basis einer neuen Produktgeneration?“

Dr. Frank Siegel

Wissenschaftlicher Mitarbeiter

Sächsisches Textilforschungsinstitut e. V.

Kay Ullrich

TITV Greiz

Thema: „3D Druck und Textil – Ein Haftungsthema“

Dr.-Ing Tobias Laumer

Leiter Prozesstechnik Kunststoffe

Bayerisches Laserzentrum GmbH

Michael Knaak

Senior Technical Consultant

Stratasys GmbH

 
Fabian Winopal

CEO/Founder

Tatcraft