KARL MAYER NEWS

An exhibition full of future opportunities !!!

Digitalisation and sustainability – the top themes of KARL MAYER’s presentation at ITMA ASIA + CITME, 15.–19.10.2018, stand B 11, hall 4, in the National Exhibition and Convention Center in Shanghai

KARL MAYER will be presenting its latest innovations at ITMA ASIA + CITME, which will be held from 15 to 19 October 2018. This global player is using its latest developments to tackle the changes taking place in the world today.

“The mega trends of digitalisation and sustainability are changing the world as we know it. As an innovative global market leader, we see these changes as an opportunity for our customers. At ITMA ASIA+ CITME, we will be showing our visitors how KARL MAYER is implementing these strategic themes, digitalisation and sustainability by delivering integrated solutions offering a wide range of advantages,” says KARL MAYER’s Managing Director, Arno Gärtner.

KARL MAYER can be found in the Exhibition and Convention Center in Shanghai on stand B 11, hall 4, where a new umbrella brand will be launched, offering innovative digital solutions known as the KARL MAYER Digital Factory, which was introduced last year. A look at KARL MAYER’s CLEANER.PRODUCTIONS will also be on the cards. Other highlights include a performance show of the latest generation of machines, a fashion show showcasing decorative, trendsetting fabrics, and a presentation of the Technical Textiles centre of excellence. An in-house show at KARL MAYER (CHINA) in Changzhzou will also be held at the same time as the fair, scheduled for 15 to 18 October.

Development of the best digital solutions

As a pioneer in textile machinery building, KARL MAYER is following a broad digitisation strategy. An important element of this strategy is to support its customers with new digital solutions at a market leader level.

The initiatives for this strategy are being coordinated by Antonia Gottschalk, the Head of Digitisation. The expertise for doing this is based on an efficient network. Since March 2018, KARL MAYER has been part of ADAMOS, an alliance made up of industrial and software companies. At the end of 2017, KARL MAYER also set up its own start-up company in Frankfurt, known as the Digital Factory, for developing new, innovative digital business models, products and services. In future, these will be combined under a new umbrella brand, which is being launched at ITMA ASIA + CITMA. “Management is focusing on the KM Digital Factory. Together with our involvement in ADAMOS, the new company will enable us to quickly make the best digital solutions available for delivering maximum benefit to our customers,” says Arno Gärtner.

Networked machines

Knowing what is going on and being informed at all times, regardless of where we are – mobile digital solutions have been making inroads into out daily life for many years now and, have changed our perception of what is current.

For the first time, KARL MAYER will present its own solution for networking its machines. This digital solution will provide its customers with transparency in real time regarding the performance of their machines, and can be used in the company’s own network with very little modification.

Integrated sustainability

“We care about your future” is what KARL MAYER is all about. Its philosophy is to take responsibility also for future generations. What KARL MAYER is doing to promote sustainability will be on show at the fair and on the internet at www.CLEANER.PRODUCTIONS.

The environmental aspects of this include the LEO® Low Energy Option, which should enable energy consumption during machine operation to be reduced by between 9.5 and 13 %, depending on the type of machine. Costs and CO2 emissions should be reduced at the same time.

Intelligent, end-use-applicable concepts should also reduce environmental loads, as a technology transfer project being carried out by the central government and regional authorities in Wujiang Shengze, China, is demonstrating. One of the aims of this project is to replace the environmentally harmful looms in this industrial area with KARL MAYER’s warp knitting machines offering a comparable product portfolio. The TM 3, with its broad product portfolio, is a particularly good alternative. This tricot machine will be shown in operation at the exhibition, together with examples of its uses.

KARL MAYER will be showing the TERRY.ECO concept for the environmentally friendly production of terry goods, the core element of which is the TM 4 TS-EL machine. Depending on the type of product being produced, this cotton terry warp knitting machine can produce up to 250 % more fabric and consumes approximately 87 % less energy per kg of textile than air-jet looms. Sizing can be dispensed with, which reduces energy, water and effluent loads. The TM 4 TS-EL will be on show at KARL MAYER’s in-house show in Changhzou.

With its PROSIZE® sizing machine, KARL MAYER is offering weaving companies involved in the production of terry goods a sizing machine based on the concept of sustainability. With this machine, the sizing agent is applied by a highly efficient, intelligent process. Compared to conventional methods, this reduces the consumption of sizing agents by up to 10% and reduces bath volumes. A reduced size consumption also means less energy consumption when preparing the chemicals and for desizing. Also, less effluent is produced. The core element of the PROSIZE® system, the VSB Size Box, will be on show in Shanghai.

The latest generation of machines

For the first time, the widest high-speed tricot machine in the world, the HKS 3-M, 280″, will be demonstrated to the public in operation at the exhibition. This new machine delivers maximum flexibility for the usual product repertoire. Unlike previously, articles of different widths and also more fabric webs can be produced simultaneously on just one machine. The unique performance of this machine will be demonstrated as it produces a velour fabric in a gauge of E 32.

The first TM model with KAMCOS® 2 facility is also being showcased. KARL MAYER’S TM 3, 186″, equipped with the next generation of the KARL MAYER Command System, retains the tried-and-tested features of the HKS version. These include an operator interface with functions based on smartphone technology and an integrated laser stop system as well as data access via mobile devices using the KARL MAYER CONNECT app. In Shanghai, this efficient, flexible production machine will be producing a tough fabric in a gauge of E 32 with ecological benefits. This textile can be used as a substitute for fabrics produced by water-jet weaving, with its high effluent loads.

For the warp preparation sector, KARL MAYER will also be showing the innovative VSB Size Box at the fair. Instead of the usual immersion and bath application process, the Prosize® operates with three, highly turbulent, homogeneous application zones, spray bar technology and a subsequent application/squeeze roller system. This reduces the volume of the size bath and sizing additives, thus decreasing the environmental loads. Other benefits include an extremely uniform size film and less fibre dust – guaranteeing maximum weaving efficiency – and a 20% larger yarn coating zone.

KARL MAYER will also be showcasing the ISODIRECT direct warping machine – a world first with a unique cost:benefit ratio. This all-round machine can process every type of staple-fibre yarn and produces high-quality beams at warping speeds of up to 1,000 m/min-1.

Textiles with trendsetting features

This demonstration of KARL MAYER’s technology and strategies will be complemented by a presentation of the wide range of applications of warp-knitted fabrics. Seductive lace, high-performance fabrics for sportswear, original creations for athleisure wear, and apparel fabrics with a certain pizzazz – KARL MAYER’s textile innovations show the wide variety of warp-knitted textiles available and are setting the trend in every sector.

Building on textiles

KARL MAYER has the right technology and expertise to cater for a wide range of applications in the technical textiles sector. The company’s weft-insertion, biaxial and multiaxial warp knitting machines can be found in the plants of manufacturers of inlays, tarpaulins and advertising substrates, as well as in those of producers of geogrids, composites and automotive fabrics. The focus of the exhibition at ITMA ASIA + CITME will be on textiles for the construction sector. The Chinese construction sector is one of the growth areas in the country but, unlike the construction industries in Europe and America, for example, the Chinese building industry focuses on conventional materials. Textiles can offer the construction sector many advantages, especially when used in concrete components. By replacing conventional steel reinforcements with carbon- or glass-fibre textiles, the amount of concrete used can be reduced by up to 70%. Other promising applications for warp-knitted structures are in tear-resistant plaster grids for increasing the tear resistance within the plaster, self-adhesive tape for repairing holes and cracks in walls, cost-effective, flexible roof canopies and bitumen roofing materials with excellent mechanical properties. Examples of these types of textiles will be used to illustrate the advantages of warp-knitted building textiles during the exhibition.

An in-house show with exclusive machines

KARL MAYER (CHINA) is sending out invitations to attend an in-house show with performance demonstrations of selected machines for the Chinese market from 15 to 18 October in Changzhzou.

The new COP 5 M-EL, 180″ five-bar tricot machine will be unveiled to the public for the first time in Changzhzou. This machine will be producing a shoe fabric in a gauge of E 20, just one of the fabrics in its extensive production repertoire. The electronic guide bar control facility and five guide bars make the machine extremely flexible.

A new machine will be representing the RD machine series at the in-house show. This new model is part of the RD 7 series and puts the emphasis on speed. This high-speed machine will be producing a shoe fabric at the in-house show in a gauge of E 22, and will be demonstrating a speed that has never been achieved before.

KARL MAYER’s TM 4 TS-EL is a versatile terry warp knitting machine for processing cotton. In Changzhou, the TM 4 TS-EL, 186″ will be producing a double-face fabric in a gauge of E 28 with fluffy micro-fibres on the outside and absorbent cotton on the inside. Its technology makes this machine an environmentally friendly alternative to looms.

From its range of warp preparation equipment, KARL MAYER will be showing a LONG CHAIN BEAMER (LCB) and a BALL WARPER (BW) for processing denim, especially for rope dyeing. The efficiency of the LCB may be up to 20 % higher than comparable machines, and the beams are of the highest quality. The BW produces high quality warp balls and guarantees maximum performance. KARL MAYER will also be showing the ISOWARP, a sectional warping machine with an excellent cost:benefit ratio for standard applications. Compared to similar machines on the market, the performance of this machine may be as much as 30 % higher in warp preparation, and weaving efficiency may be up to 3 % higher.

KARL MAYER MORE INFO AT ITMA ASIA & CITME

  • An exhibition full of future opportunities

    The latest generation of machines + Digitalisation and sustainability – the top themes of KARL MAYER’s presentation

    THE LATEST GENERATION OF MACHINES

    • HKS 3-M, 280” – The world’s widest tricot machine
    • TM 3 – The first TM model with KAMCOS® 2 facility
    • VSB Size Box – The innovative part of the PROSIZE® which reduces the volume of the size bath and sizing additives
    • ISODIRECT – a world first allround direct warping machine with a unique cost:benefit ratio for standard applications

    DEVELOPMENT OF THE BEST DIGITAL SOLUTIONS

    • LAUNCH OF A NEW UMBRELLA BRAND FOR DIGITAL SOLUTIONS
      As a pioneer in textile machinery building, KARL MAYER is following a broad digitisation strategy. An important element of this strategy is to support its customers with new digital solutions at a market leader level. 
      For the first time, KARL MAYER will present its own solution for networking its machines. This digital solution will provide its customers with transparency in real time regarding the performance of their machines, and can be used in the company’s own network with very little modification.

    INTEGRATED SUSTAINABILITY CONCEPT

    • CLEANER.PRODUCTIONS – environmentally friendly advantages of warp knitted textiles compared to other production methods
    • LEO – Low-Energy-Option
    • TERRY.ECO – Sustainability and the conservation of energy and resources when producing terry fabrics

    “We care about your future” is what KARL MAYER is all about. Its philosophy is to take responsibility also for future generations. What KARL MAYER is doing to promote sustainability will be part on show at the fair.

  • IN-HOUSE SHOW

    Special Event for registered visitors

    With its extensive range of products, the In-house Show is a must for the warp knitting sector, and it is an ideal opportunity for visitors to complement what will be on show at ITMA ASIA + CITME

    • NEW: COP 5-M -EL – fist live demonstration of the new five-bar trikot machine
    • NEW: RD 7 – new double-raschel which puts the emphasis on speed and operates with a optimized trick plates distance
    • TM 4 TS-EL – versatile terry warp knitting machine with an increased output
    • TMJ 4/1-T  – terry machine with jacquard
    • an efficient direct warping machine DS OPTO EC for every running length and application
    • LONG CHAIN BEAMER (LCB) and BALL WARPER (BW) for processing denim, especially for rope dyeing
    • ISOWARP – a sectional warping machine with an excellent cost:benefit

    Registration

    The registration is now open till 12th October. Only persons registered in advance have access to the In-House Show. 
    For additional information please email to 

    Register now

    How to get to the In-house Show:

    VIA BUS TRANSFER

    We offer a bus transfer from ITMA Asia (NECC / Shanghai) to KARL MAYER (China) and back.​

    • Meeting point: 11:45 AM at the KARL MAYER Booth (Hall 4 / B11) 
    • Leave 12:00 PM:  leave exhibition grounds for KARL MAYER China, arrival approx. 14:30 pm
    • Return 16:30 PM:  back to Shanghai Hongqiao, arrival approx. 19:00 pm
      After the bus returns back to Shanghai, the bus will let you get off close to station of metro line 2.

    BY YOUR OWN / SELF DRIVER

    Please come directly to KARL MAYER (China)​
    No.518 Changwu Road213166 Wujin District, Changzhou City, Jiangsu Province
    google maps / baidu

    Contact:

    For additional information please email to  or contact Chen, Juan directly 0086 519 86198847

REGISTRATION

KARL MAYER In-house Show
The registration will be open till 12th of October.

KARL MAYER – ITMA ASIA + CITME and an In-house Show 15. – 19. October 2018 / China

An exhibition and In-house Show full of future chances will be waiting for you.

At the upcoming ITMA ASIA + CITME to be held from 15. to 19. October 2018 at the National Exhibition and Convention Center in Shanghai, the world market leader will be present on Stand B 11, H 4, with an innovation show on the mega trends of our time.

Moreover, during the trade fair in Shanghai, KARL MAYER will invite its guests to take part in an in-house show at its plant in Changzhou. Here, the visitors will have the opportunity to see a performance show of the new COP 5 EL and many other market-oritented developments.

We are looking forward to your visit!

at ITMA ASIA + CITME In-house Show
15. – 19. October 2018
National Exhibition & Convention Center in Shanghai
Stand B 11, H 4 
15. – 19. October 2018
KARL MAYER China
Changzhou City / Wujin District

 

 

125,000th KARL MAYER machine crowns a 50-year partnership with Dong-Jin Textile from the sports shoe industry

One company has hit the ground running – with a milestone machine

Dong-Jin Textile is one of the most well-known players in the sports shoe fabric sector and works for big brand names worldwide. This company has its headquarters in Busan / Korea, and just like sports men and women, speed and agility are what have made it successful – and this manufacturer also demands the same high performance of its production machines. In the spring of 2018, Dong-Jin Textile expanded its production capacity with the acquisition of one of KARL MAYER’s newest machines. This new jacquard raschel machine has been specifically modified and offers maximum patterning flexibility. It operates at a unique speed of 1,200 min-1 and is also special for another reason – it is the 125,000th machine to be delivered by KARL MAYER and is a measure of the company’s high level of success.

This high-speed machine was sent quickly by air on its way to the customer’s site. It reached Incheon Airport on 14th July and immediately went into production, without first undergoing processing trials in the customer’s research department, which had been the original plan.

 

Always one step ahead

Dong-Jin Textile exclusively manufactures shoe fabrics for the sports industry and is one of the biggest global suppliers in this sector. This company is also one of the biggest in the country’s textile sector. It has a workforce of 600 and also uses a large number of fabric producers acting as subcontractors in the southeast of the Korean Peninsula especially. Dong-Jin Textile owes its success to its exceptional closeness to the market. The president, Woo Chul, Choi, has excellent contacts with the brand names operating in the sports shoe sector, and provides them with textile solutions so that they are always one step ahead. This entrepreneur has demonstrated his pioneering spirit in his trendsetting collections. He has taken new paths with great decisiveness. “I greatly value Mr. Choi as a business partner. He has a phenomenal knowledge about warp knitting. It is amazing that the president of such a company knows so many details about our machines. He is able to make quick decisions and always keeps his word.” says Rainer Mueller. KARL MAYER’s Sales Director for Asia deals directly with the president when handling machine projects. He relies on high-tech machines to produce his innovative textiles – on the machines manufactured by KARL MAYER.

A long-standing partnership

Dong-Jin Textile and KARL MAYER have been working together for 50 years. The company founder, Byung Kil, Choi and his son, Woo Chul, Choi, who now manages the company, have bought more than 250 warp knitting machines – exclusively from KARL MAYER with the support of its long-term partner Illies. The company has invested in high-speed tricot machines, double-bar and jacquard raschel machines as well as warping machines.

The machines are operating in several factories in South Korea and Vietnam. Dong-Jin Textile also intends manufacturing in Indonesia from the second half of 2019. KARL MAYER is ready to give Mr. Choi the utmost support for this new challenge.

Interview statements by Woo Chul, Choi, President of Dong-Jing Textile, on the occasion of the handover of the anniversary machine:

The KARL MAYER Digital Factory completes its leading management

Maximilian Kürig strengthens the management of the KARL MAYER start-up company

KARL MAYER relies on digitalisation, for this purpose the company pursues a broadly structured strategy, and focuses, among other things, on the development of new digital solutions. The necessary competence comes from an efficient network. In March 2018 KARL MAYER joined ADAMOS, an alliance of industrial and software companies. Moreover, in November 2017 this market leader and sector’s pioneer set up its own software start-up company for the development of advanced digital competences. The new member of the KARL MAYER Group, the KARL MAYER Digital Factory, develops groundbreaking digital business models, products and services, representing the future success. „The management relies on the KARL MAYER Digital Factory. This new enterprise is the most important basis for our ability to quickly provide the best digital solutions with maximum benefit to our customers“, says Arno Gärtner, CEO of the KARL MAYER Group.

In July 2018 the KARL MAYER Digital Factory received an additional Managing Director. In the future, Antonia Gottschalk, Head of Digitalisation at KARL MAYER, will be supported at top executive level by Maximilian Kürig. The graduate mechanical engineer is committed to KARL MAYER’s pioneering spirit. „I would like to establish a profitable subsidiary that sets the pace of innovations for software and digital solutions in machine and plant engineering, at the same time giving our customers the certainty to be able to make best use of the chances offered by digitalisation.“ The KARL MAYER Digital Factory is the company’s fourth Business Unit, in addition to Warp Knitting, Warp Preparation and Technical Textiles, and its aim is to ensure the success of the KARL MAYER Group.

To achieve his goals, Maximilian Kürig relies on his staff members. He sees himself as pioneer and wants to be an example for his employees, leaving them enough room for creativity, progress und foresight. Besides, the new Managing Director has gained extensive professional experience in the sector. Over several years he has successfully been managing a lot of software projects in different industrial branches, and he has made a name for himself in the fields of software and innovations. This expert knows how it is possible to successfully establish a digitalisation and software business. „I have accompanied the preparation and implementation of numerous software and digitalisation solutions, and in the course of this I have developed an in-depth technical, sector-specific and entrepreneurial understanding. However, I have also come to know the pitfalls of the topic“. In other words: Maximilian Kürig took over a new position, but he does not break new ground. With his know-how and commitmet, he offers important requirements for achieving the success of the KARL MAYER Digital Factory.

About the KARL MAYER Digital Factory

The KARL MAYER Digital Factory was founded on 3. November 2017, with registered office in Frankfurt/Main. Main aim of the enterprise is a fast and flexible development of new digital solutions, offering perceptible added value for the customers.

The company employs a team of software specialists and technology experts.

It can rely on the sound financial basis, on the know-how and on the capacities of the KARL MAYER Group. The innovative world market leader, KARL MAYER, is the sole shareholder of the young software start-up company.

Contact details:

KARL Mayer Digital Factory GmbH

Carl-Benz-Str. 21, D-60386 Frankfurt

Marlies Müller

Tel.: +49 172 209 2137

E-mail: Marlies.Mueller@km-df.com

Highsun And KARL MAYER — Teaming In The Direct Warping Sector

OBERTSHAUSEN, Germany — July 30, 2018 — Highsun has made a name for itself as one of the world’s largest company groups specializing in the polymerization and spinning of polyamide and in the production of spandex. The Chinese group focuses on high-quality products and on new innovations. Providing effective support for its end customers in the polyamide and elastane fiber production chain is also important for this synthetic fiber specialist.

The Highsun Group is a modern conglomerate, which combines business operations in synthetic fibers, real estate and financial services under a single umbrella.

The synthetic fiber operation employs roughly 5,000 people. The core products include Nylon and spandex yarns, as well as polyamide 6 polymer chips. Highsun also offers one-stop solutions for the textile industry. These include supplying caprolactam as the starting material for the production of polyamide 6, polyamide itself, and spandex, as well as spinning, yarn texturing, direct warping and, last but not least, dyeing and finishing. 40 billion RMB were invested in its subsidiary, Shengyuan New Materials, as a high-end facility for producing caprolactam. This company covers an area of roughly 549,000 m². Its planned annual output is 1 million metric tons and the machinery for producing the first 400,000 metric tons was successfully installed and launched into production in July 2017.

Environmental protection is a top priority for Highsun in all its business operations. Its products are certified in accordance with the OEKO-TEX® Standard 100. They are sold on the domestic market but are also well established globally. Among its customers are textile companies in 30 countries, mainly in Asia, Europe and North and South America.

Experience and expertise in warping

Alongside Shengyuan New Materials, Highsun Warping plays an important part in complementing the range of products for producing polyamide and spandex, i.e. in the processing chain. This arm of the group supplies sectional warp beams of the highest quality to improve the product quality in warp knitting. This is achieved by using high-speed machines and having extensive knowledge and expertise.

Highsun relies on many years of experience in direct warping. An early subsidiary of the company, the GuiFuRen Company, began warping spandex in 1994 using one of the first elastane warping machines supplied by Karl Mayer. In the years that followed, Highsun continuously expanded its research and development operations and improved its product quality. With its high-end, innovative products, Highsun won many customers and set up a number of long-lasting partnerships.

Managers in warp knitting companies were increasingly coming to the conclusion that high-quality warp beams could have a clear, positive influence on their production, but they also knew that extensive experience, technical knowledge and innovative machines were needed. Many warp knitting companies could not meet these requirements, which restricted the development of their businesses.

For this reason, in 2011, Highsun invested in a large number of Karl Mayer’s warping machines for processing warp beams with elastane yarns, and set up its own warp knitting and warping department. Its customers could obtain high-quality warp beams for warp knitting direct from Highsun. Warp knitting companies were keen to exploit this facility, which consequently promoted the expansion of the Highsun Group.

A machine with an impressive performance

20 of Karl Mayer’s elastane warping machines, types DSE HH and DSE 21/21 EC, are currently running in Highsun’s factories. Yarns having counts of from 18 to 640 den can be processed on these warp preparation machines, and beams carrying between 30 and 1,090 warp yarns can be warped. The company also invested in a number of DS 50/32 DNC direct warping machines at the end of 2017 to enable it to produce super-sized beams.

With its flexible and modern warping operations, Highsun can meet the needs of its customers most effectively. Deliveries within the area can be made in less than 24 hours after the order has been placed. This exceptional service and high warp beam quality have impressed many brand names, including Carvico. This well-known warp knitting specialist has been working with Highsun since 2017. The spandex beams are exported directly to Carvico’s factory in Italy and fully meet the stringent requirements of the company’s own quality assurance specifications.

Cooperation that benefits the customer

This Chinese company intends to continue cooperating with Karl Mayer in the future in order to fulfil its obligations as a reliable partner. “Highsun will strengthen and consolidate its strategic cooperation with Karl Mayer in the future. Our company group will continue to concentrate on the production of and research into top-quality polyamide and spandex, as well as high-end products to put us at the forefront of healthy development within the sector,” says Mei Zhen, general manager of Highsun Synthetic Fiber Technologies Co. Ltd, one of the companies in the Highsun Group.

As part of this partnership, Highsun employees and their warp knitting customers can attend courses held by the Karl Mayer Academy China. During these training courses, instructors and service specialists at Karl Mayer (China) provide the customers of both companies with useful information on setting up, operating and maintaining warp knitting machines. On 7 May 2018, a four-day course was again held in Highsun Synthetic Fiber Technologies Co. Ltd. Alongside of the warp knitting introduction given by Karl Mayer instructors, the Head of the warp preparation section there, Wang Wenyong, provided additional information by speaking about how to improve the warp quality and on the relationship existing between warp beam quality and warp knitting efficiency. “There is every reason to take part in the courses to enable us to promote the success of our mutual customers,” says Wang Wenyong.

Warping elastane on Karl Mayer’s DSE machines

The DSE HH and the DSE 21/21 EC produce warp beams from elastane and deliver an exceptional level of performance. Their vertical process management system enables even very fine yarns to be processed gently, the freely running yarn permits the machines to be operated easily, and the machines are extremely flexible in terms of the stretching conditions. Stretching of the warp yarns on the beam can be selected from between 15 and 100% and is adjusted in three stretching zones. In the pre-stretching zone, the yarn coming from the creel is stretched by between 50 and 210 percent. Following this, the yarns pass via a positively driven overrun roller system in an intermediate zone, where they can contract again. In the final stretching zone, the yarn is given its final stretch up to the winding point, and this may be between 15 and 100 percent.

GoLite produces ligthweight outerwear with a focus on running and yoga. A big focus is put on sustainability with garment made of recycled materials and sustainable chemistry.

A camera monitoring system interrupts the machine operation in the event of any yarn breakages. If the machine is stopped at full speed, a sophisticated system for synchronizing the brakes guarantees reliable control of the yarn sheet. A computer-based circumference control system ensures that all the beams in a set are absolutely identical.

Posted July 30, 2018

Source: KARL MAYER Textilmaschinenfabrik GmbH

ITMA Asia + CITME 2018 Exhibitor Preview: KARL MAYER

OBERTSHAUSEN, Germany — August 23, 2018 — Digitalisation and sustainability – the top themes of KARL MAYER’s presentation at ITMA ASIA + CITME, 15.–19.10.2018, stand B 11, hall 4, in the National Exhibition and Convention Center in Shanghai

KARL MAYER will be presenting its latest innovations at ITMA ASIA + CITME, which will be held from 15 to 19 October 2018. This global player is using its latest developments to tackle the changes taking place in the world today.

“The mega trends of digitalisation and sustainability are changing the world as we know it. As an innovative global market leader, we see these changes as an opportunity for our customers. At ITMA ASIA+ CITME, we will be showing our visitors how KARL MAYER is implementing these strategic themes, digitalisation and sustainability by delivering integrated solutions offering a wide range of advantages,” says KARL MAYER’s Managing Director, Arno Gärtner.

KARL MAYER can be found in the Exhibition and Convention Center in Shanghai on stand B 11, hall 4, where a new umbrella brand will be launched, offering innovative digital solutions known as the KARL MAYER Digital Factory, which was introduced last year. A look at KARL MAYER’s CLEANER.PRODUCTIONS will also be on the cards. Other highlights include a performance show of the latest generation of machines, a fashion show showcasing decorative, trendsetting fabrics, and a presentation of the Technical Textiles centre of excellence. An in-house show at KARL MAYER (CHINA) in Changzhzou will also be held at the same time as the fair, scheduled for 15 to 18 October.

Development of the best digital solutions

As a pioneer in textile machinery building, KARL MAYER is following a broad digitisation strategy. An important element of this strategy is to support its customers with new digital solutions at a market leader level.

The initiatives for this strategy are being coordinated by Antonia Gottschalk, the Head of Digitisation. The expertise for doing this is based on an efficient network. Since March 2018, KARL MAYER has been part of ADAMOS, an alliance made up of industrial and software companies. At the end of 2017, KARL MAYER also set up its own start-up company in Frankfurt, known as the Digital Factory, for developing new, innovative digital business models, products and services. In future, these will be combined under a new umbrella brand, which is being launched at ITMA ASIA + CITMA. “Management is focusing on the KM Digital Factory. Together with our involvement in ADAMOS, the new company will enable us to quickly make the best digital solutions available for delivering maximum benefit to our customers,” says Arno Gärtner.

Networked machines

Knowing what is going on and being informed at all times, regardless of where we are – mobile digital solutions have been making inroads into out daily life for many years now and, have changed our perception of what is current.

For the first time, KARL MAYER will present its own solution for networking its machines. This digital solution will provide its customers with transparency in real time regarding the performance of their machines, and can be used in the company’s own network with very little modification.

Integrated sustainability

“We care about your future” is what KARL MAYER is all about. Its philosophy is to take responsibility also for future generations. What KARL MAYER is doing to promote sustainability will be on show at the fair and on the internet at www.CLEANER.PRODUCTIONS.

The environmental aspects of this include the LEO® Low Energy Option, which should enable energy consumption during machine operation to be reduced by between 9.5 and 13 %, depending on the type of machine. Costs and CO2 emissions should be reduced at the same time.

Intelligent, end-use-applicable concepts should also reduce environmental loads, as a technology transfer project being carried out by the central government and regional authorities in Wujiang Shengze, China, is demonstrating. One of the aims of this project is to replace the environmentally harmful looms in this industrial area with KARL MAYER’s warp knitting machines offering a comparable product portfolio. The TM 3, with its broad product portfolio, is a particularly good alternative. This tricot machine will be shown in operation at the exhibition, together with examples of its uses.

KARL MAYER will be showing the TERRY.ECO concept for the environmentally friendly production of terry goods, the core element of which is the TM 4 TS-EL machine. Depending on the type of product being produced, this cotton terry warp knitting machine can produce up to 250 % more fabric and consumes approximately 87 % less energy per kg of textile than air-jet looms. Sizing can be dispensed with, which reduces energy, water and effluent loads. The TM 4 TS-EL will be on show at KARL MAYER’s in-house show in Changhzou.

With its PROSIZE® sizing machine, KARL MAYER is offering weaving companies involved in the production of terry goods a sizing machine based on the concept of sustainability. With this machine, the sizing agent is applied by a highly efficient, intelligent process. Compared to conventional methods, this reduces the consumption of sizing agents by up to 10% and reduces bath volumes. A reduced size consumption also means less energy consumption when preparing the chemicals and for desizing. Also, less effluent is produced. The core element of the PROSIZE® system, the VSB Size Box, will be on show in Shanghai.

The latest generation of machines

For the first time, the widest high-speed tricot machine in the world, the HKS 3-M, 280″ (Fig. 1), will be demonstrated to the public in operation at the exhibition. This new machine delivers maximum flexibility for the usual product repertoire. Unlike previously, articles of different widths and also more fabric webs can be produced simultaneously on just one machine. The unique performance of this machine will be demonstrated as it produces a velour fabric in a gauge of E 32.

The first TM model with KAMCOS® 2 facility is also being showcased. KARL MAYER’S TM 3, 186″, equipped with the next generation of the KARL MAYER Command System, retains the tried-and-tested features of the HKS version. These include an operator interface with functions based on smartphone technology and an integrated laser stop system as well as data access via mobile devices using the KARL MAYER CONNECT app. In Shanghai, this efficient, flexible production machine will be producing a tough fabric in a gauge of E 32 with ecological benefits. This textile can be used as a substitute for fabrics produced by water-jet weaving, with its high effluent loads.

For the warp preparation sector, KARL MAYER will also be showing the innovative VSB Size Box at the fair. Instead of the usual immersion and bath application process, the PROSIZE® (Fig. 2) operates with three, highly turbulent, homogeneous application zones, spray bar technology and a subsequent application/squeeze roller system. This reduces the volume of the size bath and sizing additives, thus decreasing the environmental loads. Other benefits include an extremely uniform size film and less fibre dust – guaranteeing maximum weaving efficiency – and a 20% larger yarn coating zone.

KARL MAYER will also be showcasing the ISODIRECT direct warping machine – a world first with a unique cost:benefit ratio. This all-round machine can process every type of staple-fibre yarn and produces high-quality beams at warping speeds of up to 1,000 m/min-1.

Textiles with trendsetting features

This demonstration of KARL MAYER’s technology and strategies will be complemented by a presentation of the wide range of applications of warp-knitted fabrics. Seductive lace, high-performance fabrics for sportswear, original creations for athleisure wear, and apparel fabrics with a certain pizzazz – KARL MAYER’s textile innovations show the wide variety of warp-knitted textiles available and are setting the trend in every sector.

Building on textiles

KARL MAYER has the right technology and expertise to cater for a wide range of applications in the technical textiles sector. The company’s weft-insertion, biaxial and multiaxial warp knitting machines can be found in the plants of manufacturers of inlays, tarpaulins and advertising substrates, as well as in those of producers of geogrids, composites and automotive fabrics. The focus of the exhibition at ITMA ASIA + CITME will be on textiles for the construction sector. The Chinese construction sector is one of the growth areas in the country but, unlike the construction industries in Europe and America, for example, the Chinese building industry focuses on conventional materials. Textiles can offer the construction sector many advantages, especially when used in concrete components. By replacing conventional steel reinforcements with carbon- or glass-fibre textiles (Fig. 3), the amount of concrete used can be reduced by up to 70%. Other promising applications for warp-knitted structures are in tear-resistant plaster grids for increasing the tear resistance within the plaster, self-adhesive tape for repairing holes and cracks in walls, cost-effective, flexible roof canopies and bitumen roofing materials with excellent mechanical properties. Examples of these types of textiles will be used to illustrate the advantages of warp-knitted building textiles during the exhibition.

An in-house show with exclusive machines

KARL MAYER (CHINA) is sending out invitations to attend an in-house show with performance demonstrations of selected machines for the Chinese market from 15 to 18 October in Changzhzou.

The new COP 5 M-EL, 180″ (Fig. 4) five-bar tricot machine will be unveiled to the public for the first time in Changzhzou. This machine will be producing a shoe fabric in a gauge of E 20, just one of the fabrics in its extensive production repertoire. The electronic guide bar control facility and five guide bars make the machine extremely flexible.

A new machine will be representing the RD machine series at the in-house show. This new model is part of the RD 7 series and puts the emphasis on speed. This high-speed machine will be producing a shoe fabric at the in-house show in a gauge of E 22, and will be demonstrating a speed that has never been achieved before.

KARL MAYER’s TM 4 TS-EL is a versatile terry warp knitting machine for processing cotton. In Changzhou, the TM 4 TS-EL, 186″ will be producing a double-face fabric in a gauge of E 28 with fluffy micro-fibres on the outside and absorbent cotton on the inside. Its technology makes this machine an environmentally friendly alternative to looms.

From its range of warp preparation equipment, KARL MAYER will be showing a LONG CHAIN BEAMER (LCB) (Fig. 5) and a BALL WARPER (BW) (Fig. 6) for processing denim, especially for rope dyeing. The efficiency of the LCB may be up to 20 % higher than comparable machines, and the beams are of the highest quality. The BW produces high quality warp balls and guarantees maximum performance. KARL MAYER will also be showing the ISOWARP, a sectional warping machine with an excellent cost:benefit ratio for standard applications. Compared to similar machines on the market, the performance of this machine may be as much as 30 % higher in warp preparation, and weaving efficiency may be up to 3 % higher.

Posted August 23, 2018

Source: KARL MAYER Textilmaschinenfabrik GmbH

KARL MAYER AT FEBRATEX 2018 / BRASIL

 

Visit us at #FEBRATEX 2018! In only one week from today we will be happy to welcome you at our Stand No 67/68/81/82, sector 1, street 6 in Blumenau, Brasil. One of our highlights will be the presentation of a HKS 3-M. We can’t wait to meet you!

FCEM | Febratex Group is a 100%-Brazilian company known as the main business fair promoter around the country. Throughout its 25 years of existence, the company has become a reference within the national and international markets as the only specialist in business fairs in Brazil focused on development and new technologies for the textile chain.  http://www.fcem.com.br

Karl Mayer’s Exhibition Full Of Future Opportunities Presented At ITMA ASIA + CITME

OBERTSHAUSEN, Germany — July 26, 2018 — At the upcoming ITMA ASIA + CITME to be held October 15-19, 2018, at the National Exhibition and Convention Center in Shanghai, Karl Mayer will be present on Stand B 11, H 4, with an innovation show on the mega trends of our time, demonstrating how it is possible to implement such major topics as innovations, digitization and sustainability.

As far as digitization is concerned, Karl Mayer underlines its position as the undisputed number one in the market. For the development of new digital solutions with high customer benefit, Karl Mayer recently set up its own company. Karl Mayer’s new, digital brand will be launched at ITMA ASIA + CITME.

Concerning the topic of sustainability, the company will provide versatile solutions under the motto “Cleaner. Productions“. These include new warp knitting machines which have a lower energy consumption due to their intelligent technology, and application concepts with increased advantages for the environment. One of the highlights will show how it is possible to replace formerly mainly woven articles by warp-knitted textiles as an ecological alternative. An example in this respect is TERRY.ECO for the manufacture of terry articles.

The warp preparation business unit will be displaying a sizing machine with minimum resource consumption. Less demand for water, energy and sizing agents also means less costs and, thus, even more advantages for the customers. The technical core of the machine with focus on the ecological aspect will be presented during the trade fair. Besides, a new direct beamer with improved price-performance ratio will also be premiered at ITMA ASIA + CITME.

For the production of technical textiles, Karl Mayer will be demonstrating comprehensive expertise in Shanghai. Especially in the building and construction industry it is possible to open up new, lucrative areas of application by using textiles produced on Karl Mayer machines. Important keyword here is textile concrete.

Moreover, during the trade fair in Shanghai, Karl Mayer will invite its guests to take part in an in-house show at its plant in Changzhou. Here, the visitors will have the opportunity to see a performance show of the new COP 5 EL equipped with five guide bars, as well as lace raschel machines featuring an excellent price-performance ratio, and new developments in the double-raschel and terry-fabric fields. Besides, the visitors will also have the chance to see market-oriented developments for the warp preparation business, especially for the players in the shirting and sheeting market, and in the denim sector.

In other words: an exhibition full of future chances will be waiting for Karl Mayer’s guests.

Posted July 26, 2018

Source: KARL MAYER Textilmaschinenfabrik GmbH