Sustainability and the conservation of energy and resources – thanks to efficient technical systems when producing terry fabrics

KARL MAYER can deliver effective systems with ecologically optimised solutions throughout the entire production process – for both warp knitting and warp preparation.

TM 4-TS EL – The high-speed terry warp knitting machine

Warp-knitted terry fabrics – ecological advantages for production

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


This terry warp knitting machines operates at an impressive level of efficiency – at a width of 186″ and a speed 800 min−1, the TM 4-TS EL has a daily production rate of about 1,800 kg of terry fabrics at a weight of 400 g/m2250% more than on an air-jet loom.


The TM 4-TS EL consumes roughly 87% less energy per kilogramme of produced fabric than air-jet looms, which require a large amount of energy to produce the compressed air.


The production of warp-knitted terry fabrics requires no sizing process. This saves on textile chemicals, effluent and energy to the value of roughly 0.20 US dollars/kg. This corresponds to a share of roughly 30% of the production costs (without the yarn) when producing the raw fabric.


The firm anchoring of the terry loops into the knitted construction means that warp-knitted towels, and especially bathrobes, have a longer service life than woven textiles. The ecological advantages of this include less waste, longer replacement cycles and a lower consumption of resources.

Woven terry goods – ecological production begins with warp preparation

KARL MAYER’s PROSIZE® sizing machine can offer advantages for the environmental footprint of the entire manufacturing process when producing woven terry goods. This efficient warp preparation machine operates on the basis of a prewetting principle, which involves soaking the yarn with hot water before the size is applied. To carry out this beneficial pretreatment process, the PROSIZE® has been equipped with the CSB-PW and HSB-PW size boxes, i.e. it is available as a prewetting version. This permits savings of up to 40% to be made in sizing additives and energy. 



    A groundbreaking innovation based on an innovative, patented size application technique for use in sizing.


Busi enhances sock toe-closing options on Rimaglio system

Brescia – Sock knitting machine specialist Busi Giovanni has enhanced the performance of its Rimaglio technology, the renowned, automatic, stitch-by-stitch toe-closing device.

The Brescia-based firm says it is constantly looking to improve the reliability and versatility of the Rimaglio technology. This latest upgrade means it is now possible to knit the last course of stitches all around the item’s body, effectively 360 degrees.

This method means that the sock manufacturer can fix the end part of a tube, with both a single welt or a double one, to prevent it from unwinding.

This third version of the Rimaglio system is located on the left-hand side of the machine, which means the knitting technician still has full accessibility to the knitting head.

The sequential operation of the new device starts with the yarn finger head being raised when sock knitting has been completed. The cylinder then stops in a pick-up position with the help of a mechanical clutch.

The knitting head is then raised and the toe-closing device swings across and aligns itself exactly above the cylinder needles. It is then lowered to a position where pick-up elements position themselves precisely onto these needles. Individual knitted loops are then transferred from the cylinder needles on to the toe-closing device. The sock is then picked up and the arm swings the device back into its position underneath the tubular sock-turning piston on the left-hand side of the machine. The knitting head is closed again and knitting of the next sock commences.

As knitting of the next sock commences, the completed sock is pushed upwards and turned inside out by a sock-turning tube. This means stitching of the toe occurs on the inside of the sock to replicate traditional linking.

Next, two half-crowns, on which the last knitted course is located, close like a jaw superimposing the two halves of the sock toe on top of each other. Loops from the two separate courses are placed on the same comb. At this point, the sock toe is ready to be stitched closed, and the linking-device starts up sewing the toe area of the sock fabric with stitch-for-stitch linking. Needles pass through the loop twice to give a secure stitch and improve the elasticity of the seam.

WATERNEXT SOLUTIONS – Drinking, Wastewater and Zero Liquid Discharge

WaterNext was founded by a group of friends, all expert in water treatment, with a vision to transfer the great technological heritage of Europe to developing countries.  Through local partnerships and the application of advanced technologies, WaterNext creates reliable solutions with a high cost-benefit ratio.  The firm offers full service and assistance to customers, from plant building through sales. The team has designed and built over 3000+ plants in more than 80 countries, and has over 100 years of combined experience. Innovative technical solutions and local structures dedicated to sales, manufacture, service and support throughout the world make WaterNext the fastest growing company in the field of water, wastewater and recovery.