A company strengthens its presence on the market

Successful technical symposium on sizing technology held by KARL MAYER in India, 23.06.2018

KARL MAYER develops groundbreaking innovations for the warp preparation sector and recently presented a number of specially selected systems at a symposium in Coimbatore. The subject of this technical event on 23 June 2018 was the PROSIZE® technology for efficient and ecological sizing – an extremely interesting topic. More than 100 participants from large weaving and textile companies in southern India travelled to the event, mainly from Coimbatore, Erode, Palladam, Madurai and Namakkal. The welcoming address was accompanied by an introduction to KARL MAYER and a traditional lamp lighting ceremony. The main protagonists in this good-luck ritual were the customers, management and sales representatives of KARL MAYER India and its regional agent, A.T.E.

Fig. from left to right: a celebration to mark the start of the symposium with Kevin Socha, the Managing Director of KARL MAYER (H.K.) Ltd., Dr. Pawan Kumar Singh, the Managing Director of KARL MAYER India Private Limited, Peter Obrist, Senior Sales Manager of KARL MAYER, Milind Mirkar, the Head of Service of KARL MAYER India Private Limited, Navin Agrawal, the Business Head of A.T.E.’s Fabric Forming Division, Beat Schnurrenberger, the Vice President of Spare Parts in the KARL MAYER Business Unit Warp Preparation and Mr. CT. Valathappan President (operations) VSM Weavess India( p) Limited, Erode

A marked interest in efficient technology

Navin Agrawal, the Business Head of A.T.E.’s Fabric Forming Division, was responsible for presenting the PROSIZE® technology and explained its technical features and advantages over previous technologies. The people in the auditorium were clearly impressed by the 10% lower consumption of sizing agent, the much higher yarn coverage zone in the size box, the higher production rate and increased weaving efficiency – and these features have already impressed the Indian market. In fact, Navin Agrawal was proud to say that more than 30 PROSIZE® machines have already been installed in India and this is likely to increase. This speaker illustrated his speech with statements from users of the PROSIZE® technology, who cited the positive effects on their productivity, costs and weaving performance.

The participants in the event also listened very attentively to Navin Agrawal’s second session on the WEBSHOP SPARE PARTS system.

Even greater acceptance on an established market

KARL MAYER has a large share of the market in the south of India and enjoys an excellent reputation among commission sizing and weaving companies. The quality and reliability of the machines manufactured by this global market leader are particularly impressive. Some of the participants in the symposium said that models installed in the region 15 and 20 years ago are still running optimally. Nevertheless, there was a great deal of interest in the new technology. The Regional Sales Manager, Peter Obrist, and his sales colleagues at A.T.E. are expecting to receive a large number of enquires about orders following the symposium. The event was a huge success for everyone concerned.

So wide so good

KARL MAYER wowed a Chinese business delegation with the widest HKS in the world.

On 2 July 2018, KARL MAYER, the number one manufacturer of warp knitting and warp preparation machines, welcomed a 14-member delegation from China’s warp knitting stronghold Haining, Zhejiang province, with the world’s widest high-performance tricot machine.

The record HKS 3-M has a working width of 280″. Compared to the previously available standards, the width expansion makes it possible to produce webs of different widths with a higher number of webs. This performance impressed the visitors.

The delegation consisted of heads of the Haining Economic and Information Technology Bureau and managing directors of companies in the textile industry and other sectors.

Double the success for KARL MAYER in India

A lucrative marketing initiative – KARL MAYER participated in the VDMA Symposium and held its own Tricot Circle in May 2018

India is an important market for KARL MAYER. In 2015, this country in Southeast Asia ordered more machines than ever before from this global company, which makes it one of its three most important sales regions.

Business is taking off again after rather muted demand over the last two years. “India has a population of about 1.3 billion, who all need clothes,” says KARL MAYER’s Sales Manager, Mark Smith, when highlighting the simple truth about what is driving the Indian economy. This country is growing and KARL MAYER is in an ideal position to support this development.

Attentive listeners – the auditorium at the Tricot Circle in Daman

As well as offering high-speed machines, KARL MAYER can also offer its Indian customers expertise in warp knitting and new ideas for textile products. For example, KARL MAYER continues to participate as a speaker in the symposia held by the Verband Deutscher Maschinen- und Anlagenbau e.V., VDMA (German Engineering Federation). The conference entitled “German Technology meets Indian Textiles and Nonwovens” took place recently on 15 and 16 May 2018 in Mumbai.

KARL MAYER also regularly organises its own Tricot Circle events there. Indian textile specialist were once again invited to gather inspiration for new ideas from the latest developments in warp knitting on 17 May in Daman and on 18 May in Amritsar.

Innovations from Germany

The VDMA Symposium in India included 36 application-oriented papers presented by more than 30 well-known companies. KARL MAYER was showing its TERRY.ECO concept for warp knitting. This system for the ecological and economical production of terry goods went down well with the visitors. There were about 100 delegates in the auditorium, including many representatives from weaving companies. “The feedback was much better than we expected. Many questions were asked, which showed that weavers have understood the advantages of warp knitting for producing terry goods and are now getting to grips with the possibilities,” explained Mark Smith, a speaker from KARL MAYER.

Know-how for tricot customers

The 3rd Tricot Circle held by KARL MAYER was well attended by just under 135 delegates. Visitors came from every part of the country and some even travelled five hours by car to be there.

The focal topics of the event were the possibilities offered by high-speed tricot machines for designing a wide variety of apparel fabrics and for producing terry goods.

Many warp knitting companies in India are concentrating on producing embroidery grounds and simple fabrics for saris. However, the HKS 4-M EL can do so much more than that, as Klaus Schulze showed in his lecture. This specialist in textile product development at KARL MAYER demonstrated various transparent fabrics featuring different mesh patterns in the ground and superimposed geometric designs produced by the versatile HKS model. Possible ground constructions include classic tricot types, such as honeycomb, diamond and atlas mesh construction. Atlas and filet tulle grounds featuring integrated diamond patterns with the look of raschel-knitted fabrics can also be worked. The delegates listened very intently to what was being said and asked many technical questions. “The patterning possibilities of the four-bar HKS machine will make it popular in India,” says Mark Smith with some certainty. But a new collection of designs produced on the HKS 3-M also attracted a great deal of attention. The lightweight, voile-like fabrics are particularly eye-catching, thanks to their fine, transparent ground and dense, striped pattern blocks, and gave the visitors ideas on how to use the potential of their machines even more effectively. The HKS 3-M is already extremely well established in India.

As another highlight, Klaus Schulze demonstrated the possibilities of producing warp-knitted terry fabrics. The TM 4-TS EL is particularly interesting for this textile nation. The delegates were also interested in a paper describing a beach towel made from a double-face fabric with a cotton side for drying and a side made from polyester microfibres with cut-open loops and a colour-printed design for lying on.

Other topics also generated great deal of interest and raised many questions, including innovative textile products manufactured on the HKS machine range for the athleisure sector, intelligently designed, stylish RSJ fabrics for sportswear and leisurewear, and KARL MAYER’s Virtual Showroom.

KARL MAYER’s representatives were optimistic from the feedback they received from the delegates and the conversations they had with them during the breaks. “The market will probably recover in 2018/19,” concluded Klaus Schulze.

KARL MAYER organised the event with the support of its regional agent, A.T.E.

LACE.EXPRESS lace with bourdon cord

Vein-like patterns produce a vibrant design

The OJ 59/1 B and OJ 83/1 B LACE.EXPRESS models are the latest technical innovations in jacquard multibar raschel machines from KARL MAYER, a company that is developing its lace products all the time. A pattern was developed in time for the ITM exhibition in April 2018 in Istanbul, which allowed the LACE.EXPRESS to demonstrate all its special features when processing bourdon cord. The non-stretch, all-over lace is intended for use in apparel. Its decorative, scalloped edges can be used directly for the hems of dresses, skirts and tops. The scalloped design is continued into the lace fabric to create decorative, floral motifs in a striped arrangement. The flowers and leaves are interpreted graphically and arranged on a ground that is patterned with different designs. Narrow net patterns, organic structures and open-pored holes create a dynamic design ensemble in the ground. The types of yarns used make the design appear to move. A combination of semi-matt, textured and shimmering yarns creates an eye-catching look with contrasting and surprising effects. Bourdon cord also creates a three-dimensional effect in the surface and is representative of a new trend. Liners with an embroidered look and 3D effects are still popular for fashion lace, but a high level of know-how and expertise are needed to produce them. Polyamide yarns in a count of 1/40 f 9 were used for the pillar stitches and for incorporating the bourdon cords, which have a count of about 1,600 denier.

The yarns were processed on an OJ 59/1 B in a gauge of E 24. The LACE.EXPRESS is also available in a gauge of E 18, so that it can also be used to process thicker types of bourdon cord.

KARL MAYER’s FILESIZE is gaining ground in China in the production of printed circuit boards

Good contacts to the CCL market   

Industry 4.0, e-mobility, 5G-neworks, the Internet of Things – the modern world is changing all the time and needs one thing above all else – electronics. The huge demand for electronic components is generating good business for the printed circuit board industry and its supply chain. Huge amounts of money are being invested in this sector, especially in China. Most of all the Copper Clad Laminates (CCLs), which are the copper-laminated precursors of printed circuit board production, are supplied by Chinese companies.

Woven glass fabrics are mainly used as the carrier material in the production of CCLs. These technical textiles are treated with resin and then coated on one or both sides with a copper layer. The metal coating is subsequently etched, depending on the design of the final printed circuit boards. Products referred to internationally as printed circuit boards (PCBs) are produced, onto which electronic components can be applied or they can be combined to produce multilayered circuit boards. Types having up to 48 layers can be used in computers. Computers, mobile phones and other electronic devices are becoming smaller all the time, so that the components used inside them are also becoming smaller. The trend towards miniaturisation and the increasing demand for flexible CCL types require finer and finer woven glass fabrics. Glass yarns having increasingly smaller counts have to be processed to meet this demand – a challenge that is making KARL MAYER’s warp preparation machines the machines of choice in China.

Experience on the Chinese glass market

KARL MAYER, the well-known textile machinery producer, has been operating successfully on the Chinese woven glass fabric market with its sizing and warping machines. At the end of 2016, the electronics supply industry really started to take off and the first big orders were placed. This was followed by more big orders in the autumn of 2017 which, according to Oliver Posselt, a Sales Manager, was completely unexpected. “With the first wave of orders, we were starting from a position of a modernisation backlog in the sector,” says this sales expert in the Chinese market. “This recent demand accounts for the optimism of manufacturers. Companies are convinced that this trend will continue.” Prospects are good for 2018 and 2019 as well. The buyers include many existing customers, who are expanding or upgrading their capacity, but also companies that are new to the woven glass fabric sector.

Clean size application and gentle yarn handling

KARL MAYER owes its success on the glass market to its sophisticated warp preparation process. This process uses the principle of single end sizing: the yarns are taken off from bobbins, fed through the sizing bath, dried, and wound onto beams. These are then assembled to produce warp beams for weaving. KARL MAYER can supply the right machine technology for every processing stage. In the initial stage, the glass rovings are gently removed from creels with the aid of the ACCUTENSE computer-controlled, hysteresis yarn tensioner and fed to the FILESIZE sizing machine. This machine for processing filament yarns also focuses on process control without any loss of quality. It processes a maximum of just 800 yarns – fewer than full warp sizing machines. These do not come into contact during the treatment process, so that they are sized all over. The yarns, which are processed separately, cannot stick together in the drying zone. The separation process, which normally has to be carried out when sizing full warps and which frequently damages the glass fibrils, is now superfluous. The FILESIZE also scores points with its accurate yarn tension control during yarn transportation – an important feature, since the non-stretch glass yarn cannot tolerate any fluctuations in tension. If the tension decreases, there is a danger of loose yarns, whereas if it is too high, the yarns can be damaged. To rule this out completely, the yarn tension is monitored and controlled at several places, such as in the size box and at the entry and exit points of the drying stretch.

The zone for removing the water from the glass comprises a modern hot-air oven and a subsequent drying cylinder zone. It is important to carry out pre-drying in the hot-air oven to enable the flat cross-section of the wet yarn to take on a circular shape. The temperature of the drying cylinders is 90 to 145°C and it is monitored and controlled accurately. This accurate temperature control is needed to guarantee top processing quality and for the sectional warp beams to have a high sized quality. Four to six sectional beams are then combined to produce the warp beams destined for weaving. KARL MAYER can supply the AMR for this process. This assembly machine operates efficiently and accurately, and has proved itself many times worldwide in warp preparation.

Maximum productivity

In addition to meeting the highest quality requirements, the FILESIZE operates at an exceptionally high level of productivity. This is due to its exceptional operating reliability and unique output. This warp preparation machine operates at an impressive rate of 250 m/min-1 when processing glass under practical conditions.

Suitable for processing the next generation of fine glass yarns

The warp preparation sequence for processing glass can be adapted flexibly to suit the intended end-use, especially in terms of the tension regulation and the arrangement of the drying zone. For example, the number of drying cylinders can be varied as a function of the yarn count. “Five cylinders are usual for average counts, whereas three are sufficient for very fine counts,” explains Oliver Posselt. The coarsest types that still need to be sized have counts of 75 tex. He goes on to say, however, that fine yarns are more interesting and in higher demand. “Our customers are currently talking about 5 tex down to 1.3 tex. The challenges associated with this require a completely new type of technology. We are in an excellent position to lead the way here,” says this Sales Manager. A machine for processing extremely fine glass yarns was successfully installed in February 2018. Experience with processing these fine yarns was also gained during a project that involved the upgrading and modification of older machines.

KARL MAYER Launches The World’s Widest Tricot Machine

OBERTSHAUSEN, Germany — May 28, 2018 — KARL MAYER has extended its successful model in the HKS machine series, the HKS 3-M, by including a version having a wider working width. To complement the current machines having widths of 186″ and 218″, a version having a width of 280″ is now available. The HKS 3-M, 280″, is the widest tricot machine available on the global market, and its wider width delivers greater productivity and flexibility.

Increased flexibility for the same production repertoire

Like all the HKS three-bar machines, this new machine targets a wide variety of end-uses, from car interiors, through furniture and sportswear, to coating/backing substrates and advertising media. Fabrics processed with different widths can now be produced on one machine instead of two, which used to be the case. The simultaneous production of webs can also be increased by a factor of one, i.e. two webs can be produced on a 186″-wide machine compared to three webs on a 280″-wide machine, and three webs can be produced on a 218″-wide machine as opposed to four on the new machine. The finished fabric is wound using standard batching unit no. 6 when using the normal-width, high-speed machines, whereas the new batching unit no. 51A is used with the new machine. Batching unit no. 51A winds the fabric on friction rollers, which are driven by the fabric take-up unit.

Proven performance

As well as its new features, the HKS 3-M also offers all the usual features. For example, this high-speed tricot machine operates with a 3 x 32″ beam mounting arrangement as standard. A mounting configuration with a diameter of 40″ for beam position GB 1, and 32″ each for beam positions GB 2 and GB 3, is available as an option. Just like the machines having a smaller working width, the HKS 3-M, 280″, is available in the gauges of E 28 and E 32.

It can be equipped with the new KAMCOS® 2 efficient computer platform, the LEO® Low Energy Option for energy-efficient running, and a camera monitoring system above or below the web. A face plate under the textile web for monitoring transparent fabrics is also available as an option. The knitting motions and elements are the same as on the existing machines. This machine delivers the dependable quality typical of all KARL MAYER’s machines. It can be supervised easily and operates steadily and reliably with low maintenance requirements. It is also extremely efficient. The HKS 3-M, 280″, operates at a maximum speed of 2,200 min-1.

This extra-wide machine has just been launched onto the market, but a number of modifications are already on the agenda. The developers and engineers at KARL MAYER are currently working on a three-bar, high-speed tricot machine with an intermediate width of 238″ – with the possibility of extending this by 10″.

Posted May 28, 2018

Source: KARL MAYER

The world’s widest tricot machine: KARL MAYER launches the HKS 3-M with a working width of 280″

 

KARL MAYER has extended its successful model in the HKS machine series, the HKS 3-M, by including a version having a wider working width. To complement the current machines having widths of 186″ and 218″, a
version having a width of 280″ is now available. The HKS 3-M, 280″ is the widest tricot machine available on
the global market, and its wider width delivers greater productivity and flexibility.
Increased flexibility for the same production repertoire Like all the HKS three-bar machines, this new machine targets a wide variety of end-uses, from car interiors, through furniture and sportswear, to coating/backing substrates and advertising media. Fabrics processed with different widths can now be produced on one machine instead of two, which used to be the case.

The simultaneous production of webs can also be increased by a factor of one, i.e. two webs can be produced on a 186″- wide machine compared to three webs on a 280″-wide machine, and three webs can be produced on a 218″- wide machine as opposed to four on the new machine. The finished fabric is wound using standard batching unit no. 6 when using the normal-width, high-speed machines, whereas the new batching unit no. 51A is used
with the new machine. Batching unit no. 51A winds the fabric on friction rollers, which are driven by the fabric
take-up unit.
Proven performance
As well as its new features, the HKS 3-M also offers all the usual features. For example, this high-speed tricot machine operates with a 3 x 32″ beam mounting arrangement as standard. A mounting configuration with a diameter of 40″ for beam position GB 1, and 32″ each for beam positions GB 2 and GB 3, is available as an option. Just like the machines having a smaller working width, the HKS 3-M, 280″ is available in the gauges of
E 28 and E 32.
It can be equipped with the new KAMCOS® 2 efficient computer platform, the LEO® Low Energy Option for energy-efficient running, and a camera monitoring system above or below the web. A face plate under the textile web for monitoring transparent fabrics is also available as an option. The knitting motions and elements are the same as on the existing machines. This machine delivers the dependable quality typical of all KARL MAYER’s machines. It can be supervised easily and operates steadily and reliably with low maintenance requirements.
It is also extremely efficient. The HKS 3-M, 280″ operates at a maximum speed of 2,200 min-1.
This extra-wide machine has just been launched onto the market, but a number of modifications are already on the agenda. The developers and engineers at KARL MAYER are currently working on a three-bar, high-speed tricot machine with an intermediate width of 238″ – with the possibility of extending this by 10″.

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Do you want to experience KARL MAYER live at certain events and meet us personally?

Do you want to experience KARL MAYER live at certain events and meet us personally? You will have this opportunity at the following worldwide trade fairs and events. We are looking forward to your visit.

  • Febratex
    21/08/2018 – 24/08/2018          Febratex
    Brasil / Blumenau
  • China Composites Expo
    05/09/2018 – 07/09/2018   China Composites Expo
    China / Shanghai
  • CAITME
    11/09/2018 – 13/09/2018            CAITME
    Usbekistan / Tashkent
    ITMA Asia & CITME
    15/10/2018 – 19/10/2018      ITMA Asia & CITME  China / Shanghai
  • Composites Europe 2018
    06/11/2018 – 08/11/2018    Composites Europe 2018
    Germany / Stuttgart
    Germany Pavillon
    Stand 51 N
  • Exintex
    02/10/2018 – 05/10/2018             Exintex
    Mexico / Puebla