Time lapse videos of our new Qualiscan QMS buildings site

Thank you for visiting our construction site and your interest in our new building. As you can see, we document the construction process with a camera. We feel obliged to data protection and consider transparency in handling personal data very important. That’s why we want to inform you, why we do this and how you can exercise your rights in this case. Opens internal link in current windowFind the relevant information here (only available in German at the moment)



Mahlo employees collect their fitness bandsMahlo employees collect their fitness bands.

Fitness bands for Mahlo employees

Following upon Mahlos 1st Health Day on April 25, Siemens Health Insurance Fund distributed fitness ribbons to Mahlo employees.

During the previous Health Day, Mahlo employees were given the opportunity to individually learn which muscle regions they need to support as part of a back-check. So back problems can be reduced or avoided.

As part of the SBK action “Show Posture!” for a strong back, the Mahlo workers now picked up elastic gymnastic bands with matching instructions. With these flexible fitness bands, everyone can easily perform the exercises that suit them.

“The health day was well received by our employees. In order to further promote the health of our workforce, we are planning similar actions in the future, “says Managing Director Rainer Mestermann.

Marangoni e Lawer insieme per l’innovazione

Marangoni e Lawer insieme per l’innovazione

Marangoni e Lawer insieme per l’innovazione

Nuova tappa nel processo di ammodernamento del reparto mescole all’interno dello stabilimento Marangoni di Rovereto

 Il Gruppo Marangoni è tra i principali operatori a livello mondiale nel settore della ricostruzione degli pneumatici 

Nel 2015 era stato installato un mescolatore Intermix dotato di rotori compenetranti a distanza variabile; ora è la volta di una nuova unità per la dosatura automatica ‘Supersincro’, di ultima generazione, fornita dalla biellese Lawer.

Il completamento di questo investimento – afferma l’azienda – permetterà di innalzare ulteriormente gli standard qualitativi e la precisione di un sistema di mescolatura all’avanguardia a livello nazionale e internazionale.

“Il settore del pneumatico industriale è caratterizzato dal continuo emergere di nuove esigenze da parte degli utilizzatori finali e da una notevole velocità dell’evoluzione tecnologica – commenta Gianluca Merlo, Direttore Operations Italia di Marangoni -. Questo nuovo salto generazionale per la sala mescole di Rovereto eleverà ulteriormente il livello qualitativo garantito dal nostro stabilimento. L’investimento dimostra inoltre, ancora una volta, come Marangoni rappresenti un riferimento per società orientate all’innovazione dei processi produttivi come Lawer, che mirano a realizzare progetti di altissimo valore tecnologico”.

Fondato nel 1947 a Rovereto (TN), il Gruppo Marangoni è tra i principlai operatori a livello mondiale nel settore della ricostruzione degli pneumatici e nello sviluppo di tecnologie e macchinari per la produzione di pneumatici nuovi e ricostruiti, con 10 stabilimenti e 1.300 dipendenti in tutto il mondo.

Flameproofings Installs BRÜCKNER Line

LEONBERG, Germany — May 2018 — Flameproofings Ltd. is a producer of flame retardant coated fabrics for the upholstery and household textiles markets. The company is part of the John Holden group and a third generation family business, established more than 50 years ago. It installed and commissioned recently a state of the art BRÜCKNER coating plant in its facility in Bolton, England. The line was sold through the Brückner agent John Bradley in Macclesfield, England.

Brückner worked extensively with the Flameproofings team to define requirements and customize the design of the machine to ensure that all expectations were met or exceeded in all regards. Essential requirements were best in class heat and temperature consistency across and throughout the dryer, non-stop batch changeover and exact application as well as control of the coating media according to the customer requirements. Besides the technical features Flameproofings had high expectations in reducing the energy consumption in support of its sustainability initiatives.

Brückner’s design team, in conjunction with Flameproofings, developed a sophisticated line entry concept with two driven unwind stands, followed by a tension controlled roller accumulator to avoid length tensions and providing improved dimensional stability. The coating line is equipped with a vertical pin chain system and has specially designed air plenums for homogenous air distribution to the coated fabric. The direct gas heating system, in combination with Brückner’s staggered chamber arrangement and patented split-flow air circulation design, provide best available temperature consistency across the length and the width of the tenter dryer.

Before the order had been finalized, Brückner proofed its competence with coating trials at its technological center at the company’s headquarters in Leonberg, Germany. Regina Brückner, owner of the Brückner Group is satisfied: “We are very happy that the Technology Centre gives us the possibility to support our customers in the development of their products. Our technologists are assisting our customers at every time, giving them advice in trying out new products or new machine settings.”

Posted May 15, 2017

Source: Brückner Textile Technologies GmbH & Co. KG




US trade experts can convince themselves at NPE
Over the last years, Mahlo has established itself as a valued player in the American plastics and rubber market. At the NPE trade fair in Orlando, held from 7 to 11 Mai, industry experts can get an overview of the German machine manufacturer’s broad portfolio for quality control technology. The proficient team of Mahlo America Inc. will be happy to advice. At booth W 71 91, the latest Version of Scanner WebPro XS makes its trade fair debut.

The traversing frame of Quality measurement system Qualiscan QMS is characterized by its rugged and compact design. It is used for many applications on running web – even if space is restricted. The WebPro XS accomplishes product widths from 0, 2 to 2 meters and can host one Mahlo-sensor, which determines important parameters such as layer thickness, moisture or basis weight.

The methods used here are quite diverse. The coating thickness of almost all materials can be calculated with beta, infrared or X-rays, which penetrate the product or are reflected by it. Mahlo has developed a process for thin film utilising white light interference. For these special scenarios, for example when the surface is structured, coarse, very smooth or shiny, Mahlo has developed a special sensor with the Calipro DMS, which acts largely independently of the material finish.

Choosing from this broad range of products, plastic producers can get an individual system designed that fits exactly their demands. If they then have the data of their production line, they know where there is a need for optimization and can react. That saves not only raw material and thereby costs but also enhances the product quality.

KARL MAYER – New patterns produced on the HKS 3-M are inspiring the Turkish net curtain sector

The new architecture of transparency

The RJPC 4 F-NN jacquard raschel machine with fall plate, the RSE 4-1 raschel machine and various types of high-speed tricot machines can be used to produce warp-knitted fabrics for the net curtain sector. In Turkey the growth in sales of tricot and raschel machines has been stable over the last two years in particular.

Patterned fabrics for the embroidery sector

Turkish warp knitting companies in the net curtain sector are continuing to record good sales levels – of embroidery tulle in particular. Established types are the three-stitch, hexagonal tulle produced on high-speed tricot machines, but especially powernet fabrics produced on the RSE 4-1 in a gauge of E 32, with a beam mounting arrangement of 4×30″ and a working width of 192″. Efficient raschel machines are experiencing a real boom. “Last year, we sold considerably more RSE 4-1 machines than expected,” confirms Roland Kunze, the Managing Director of KARL MAYER’s agent, ERKO.

The HKS 3-M is another successful machine for producing embroidery grounds. This high-speed tricot machine produces open embroidery fabrics with a wide variety of ground constructions. These are in high demand, since the volume and range of designs for embroidery grounds are increasing all the time. Bastian Fritsch, a Senior Sales Manager at KARL MAYER is, therefore, certain that, “The main trend towards using the HKS 3-M will continue.” The HKS 3-M is also being used successfully to produce upholstery fabrics.

In addition to the high demand for embroidery grounds, another trend, which started in the embroidery sector itself, is fuelling the high demand for warp knitting machines. Following the motto of “Produce it yourself rather than buy it in,” conventional embroidery companies are increasingly making the move into warp knitting technology. The reasons for expanding capacity are obvious: the market outlook is positive, in-house production reduces the risks associated with quality issues and delivery times, and warp knitting is more efficient than weaving. The structure of the fabric is also more stable, which makes it more resistant to yarn damage during the embroidery process.

Curtain produced on the HKS 3-M

Delicate net curtains with integrated patterns

As well as producing fabrics for the embroidery sector, high-speed tricot machines can produce patterned net curtains – a potential that is being exploited more and more. “Net curtain producers are all looking for something new and have plenty of ideas,” says Roland Kunze. The latest developments mainly relate to the production of lightweight, transparent nets featuring a variety of grounds and integrated patterns. KARL MAYER developed such a collection of fabrics on an HKS 3-M machine in a gauge of E 28, and presented it at the ITM 2018 exhibition. With a weight of about 50 g/m², the voile fabrics are extremely light. Dense, striped, relief-like pattern blocks run across the fine, transparent ground. The ground has an attractive, silky shimmer. With its matt/shiny and thick/thin contrasts, the design ensemble is produced in a piece by the types of lapping and yarn used. To create the ground, a fine polyester monofilament yarn with a trilobal cross-section was processed in GB 2 and GB 3 in a pillar stitch and 3-needle inlay construction – which is typical of voile. This particular fibre shape creates a soft, shimmering effect. The pattern blocks are produced from a much thicker polyester multifilament yarn in a 2 x 1 or 1 x 1 lapping. The yarns are textured yarns, so that they rise up from the delicate ground to create a full, matt look. The product developers at KARL MAYER created seven patterns in this style. The variations were produced by changing the design of the grounds and pattern bands, which can be modified by changing the threading-in arrangement, the width and the location.

The HKS 3-M was demonstrating the production of this type of pattern on KARL MAYER’s stand at the ITM 2018 fair in Istanbul – a demonstration that attracted a large number of visitors. “The market is demanding more and more patterning possibilities,” observes Roland Kunze. The HKS 4-M, which is available with and without the EL facility, will become increasingly interesting for customers.

Popular jacquard net curtains are booming

With its wide production repertoire, the RJPC 4 F-NN has been widely used by Turkish manufacturers of net curtains for many years. This jacquard raschel machine with fall plate is ideal for producing chunky fabrics with a hand-made look, as well as delicate, filigree, lightweight curtains. “Roughly 300 jacquard net curtain machine are currently operating on the Turkish market and all of them are working to capacity,” says Bastian Fritsch. These fabrics, with their intricate, 3D jacquard patterns, are exported mainly to eastern Europe and Iran, as well as to western Europe, the USA, and recently to the first customers in India.

There is also a demand for more and more new alternatives for producing jacquard net curtains. “Customers are looking in particular for ways of producing grounds in a wider variety of patterns,” says Roland Kunze when summarising the feedback he had received from talking to net curtain producers.

KARL MAYER – Forging an alliance to save an endangered lake

KARL MAYER is supporting the textile industry in Shengze with restructuring its technology to guarantee a cleaner environment

Shengze lies in the Wujiang District of Suzhou in eastern China, close to Lake Taihu, and is famous for its textile industry. This area has been regarded as the silk capital of China for just under a thousand years. Companies serving the entire textile value-added chain are based there, but it is known as a centre for water-jet weaving in particular – so far, so not good, since effluent from the looms flows straight into Lake Taihu and causes huge levels of pollution. The lake is constantly beset with algae blooms, which is harmful to the drinking water supply of millions of people and endangers the fish and plant life in the lake. One of the ways in which the central government and regional authorities have reacted to the problem is to draw up a plan for transforming the textile industry in Shengze. The aim is to modernise the water-jet looms in particular, and to replace them with alternative warp knitting technology. The district and town administrations are working closely with the well-known warp knitting machine manufacturer, KARL MAYER. “The Shengze administration is firmly convinced that we have the best partner on board for implementing this project of technology transformation,” says Yang ZengXing, the Managing Director of KARL MAYER (CHINA).


The top management from KARL MAYER and ILLIES meet with companies based in Shengze and representatives of the administration in January 2018 to discuss their positions and aims for technology reform in Shengze

An experienced partner for an ambitious project

As the market leader in warp knitting machines and with a subsidiary in Changzhou, KARL MAYER is the ideal company for implementing the ambitious plans to improve the environment in Shengze – and the company has also had experience in this area of the market. This textile machinery manufacturer and its agent, ILLIES, have been supporting customers in Shengze for many years. The number of warp knitting machines installed there has been increasing, especially since 2011.

Representatives of the regional administration have been in talks with KARL MAYER since 2016 regarding the restructuring of the textile industry. A delegation of top-officials met end of January 2018 with the management of the KARL MAYER group and KARL MAYER (CHINA) in Wujiang/Shengze, and they were impressed by the innovativeness and expertise of this manufacturer. KARL MAYER (CHINA) lies just two hours by car from this area, and this is also contributing to the success of this cooperative venture.

 “I am looking forward to KARL MAYER’s support in our environmental, restructuring and modernisation project,” says Mr. Fan Jian Long, member of the Standing Committee in Suzhou Wujiang, Party Secretary and Director of Shengze and the Wujiang High-Tech Zone – and his words were very well received. “The whole top management of KARL MAYER is heavily involved with what is happening in Shengze. Our company will provide the best support in developing the warp knitting sector,” assures KARL MAYER’s group CEO, Arno Gärtner.

This support involves providing efficient machines that deliver environmental advantages by incorporating the latest technical innovations. An example of this is the LEO system, which enables considerable amounts of energy to be saved when operating the machines. KARL MAYER’s company strategy is also focusing on the concept of digitalisation. This textile machinery manufacturer is also involved with Industry 4.0. It has implemented an efficient ERP system throughout more or less the entire company group, and set up a spare parts webshop for its customers. “The future will definitely be a digital era,” says Arno Gärtner.

In addition to technical solutions and systems, KARL MAYER also brings to the Shengze restructuring and transformation project a strong service team, trained instructors for providing courses leading to qualifications but, above all, experienced R&D experts. “KARL MAYER (CHINA) has set up a project team to provide the company’s 360° support and service, as well as textile development and training for its customers in the region,” says Yang ZengXing.


New construction of Mahlo assembly hall in full swing

In November 2017 the first cut of spade took place, today the first steel girders of the new assembly hall of Saal machine builder Mahlo GmbH + Co. KG rise up into the sky. Moving in in the summer is firmly planned. Because up until now, everything is on schedule, production manager Oliver Kastl says.


“The earthworks and foundation work were completed at the end of last year right on time, as well as the building of cable routes.” The mild weather in the first winter months surely was helpful. Now, the steel construction, that is the basic structure of the hall, will be finished. Then base installation, wall covering and the roof follows. “The cold temperature of the last weeks were a challenge, of course”, so Kastl. “But the staffs of Probst Company, that install the girders high up in the air, were not impressed by sub-zero temperatures.” The next big step in the construction plan is the installation of the indoor crane, which will transport heavy parts or complete machines from point A to point B.

But before men and machines can move into their new home, the interior construction for twelve work places in assembly and the offices are made in midyear. Of course with regards to work place ergonomics and environmental protection, as Kastl confirms.

With the modern extension, Mahlo meets the need of an increased demand for measure and control technology in the world market. In addition to that, they want to further strengthen the head quarter in Saal as the only production site. 



the Ji truck



On this truck people will be able to discover the new most compact Generation of Jacquards with integrated dwell, and a Linux based controller with a friendly user interface due to the use of icons. Thanks to his low power consumption the Ji has a low ecological footprint.