The Indian Minister of State for Textile visited KARL MAYER

Indian government representatives got information about the state-of-the-art textile machinery building company in Obertshausen, 09.02.2018

On 9th February 2018 KARL MAYER welcomed the Indian Minister of State for Textiles, Mr. Ajay Tamta, at its Development Center in Obertshausen. The government representative was accompanied by Mr. Anant Kumar Singh, Secretary Government of India, Ministry of Textiles, and by other delegates from the Ministry and Consulate General. The Indian Minister took the opportunity of a business trip to Germany to learn more about the products and the manufacture of one of the most important textile machinery builders of the knitwear industry with successful business activities in India.

India‘s textile and clothing industry is on a clear growth course. The sector shows an annual plus of 12%.

KARL MAYER has been working with Indian textile companies for many years. „India is an important market for us“, explained Dr. Helmut Preßl, KARL MAYER’s CFO, when he welcomed the guests. In 2014 KARL MAYER opened its own plant in Ahmedabad, and started its own value creation in the Indian market. Today, KARL MAYER with roughly 80 highly qualified staff members and with its longstanding, experienced regional agent A.T.E. is successfully operating on site. For its business planning until 2023, the enterprise expects a continuing, above-average growth rate. The desired success should especially be ensured by new technologies, which do not only support improvements in productivity but also the change of the textile industry to sustainability.

All these new and innovative aspects could be shown to the government delegation during a presentation of machines and end-uses at KARL MAYER’s headquarters. The visitors were impressed by the high output of the machines and by the top quality of the fabrics. Some of the highlights were, among other things, solutions for sustainability such as the LOW ENERGY OPTION (LEO), which ensures significant energy savings during machine operation, and the innovative sizing machine PROSIZE®, which requires considerably less sizing agent than conventional equivalent types. But KARL MAYER does not only offer innovative machines but also textile developments ensuring success on the market. The innovative textiles, for example elastic and rigid lingery articles or fabrics for activewear and clothing, can be produced on the KARL MAYER machines in a most efficient way and in wide-ranging designs.

The secret behind this unique performance could be shown to the guests on a tour of the new assembly hall that was set up in 2017.

Learning from each other and cooperating with each other are important factors for the upcoming Indian textile and clothing industry, this was the unanimous opinion during the final discussion. KARL MAYER as world market leader is a strong partner in this respect.

KARL MAYER Reports Its Denim Business Is Booming

OBERTSHAUSEN, Germany — January 29, 2018 — Jeans are, and will continue to be, a top fashion trend, and its denim business is extremely lucrative for KARL MAYER. With its Centre of Excellence for the denim sector, Karl Mayer ROTAL, this global player can offer one-stop solutions for slasher and rope dyeing.

Compared to conventional machines available on the market, the PRODYE-S and PRODYE-R indigo dyeing machines from this Italian subsidiary consume less water, produce less waste and enable deeper, brighter indigo shades to be produced. The dye add-on as a percentage of the total yarn weight is 5.5 percent maximum. This warp preparation equipment is also highly productive. The PRODYE-S can double output when processing lightweight denim. The market has been extremely impressed by the performance offered by Karl Mayer ROTAL’s indigo dyeing machines. Demand has been increasing continuously since 2015, and has been especially high this year. Turkey, in particular, has placed a large number of orders.

A large number of orders was placed in 2017

Turkey is a lucrative market for Karl Mayer ROTAL. Many large denim producers there are already working with the PRODYE-S machine and have placed follow-up orders this year. Follow-up orders have also been received from companies in Mexico. Machines have also been delivered to companies that are new to this technology — in Turkey and Iran as well. Turkish companies are also contributing to the success of the PRODYE-R. This rope dyeing machine was only delivered in May 2017. It was sent to Algeria as part of a large project, under the auspices of TAYAL, a joint venture involving the participation of the Turkish company, Taypa. Turkey invested in another PRODYE-R machine in the autumn of this year.

Karl Mayer ROTAL invited any specialists who were interested to travel to Vietnam to see a practical demonstration of its indigo dyeing machine. One customer, who has been working with the PRODYE-S since February 2017, made his company available for the open-house show, and reported on his experiences. The event was attended by a small yet highly qualified group of people. The visitors came mainly from the host country, but also from Hong Kong, Indonesia and China. The next opportunity to see Karl Mayer ROTAL’s DENIM machines will be at the ITM International Textile Machinery Exhibition in Istanbul, which will take place from April 14-17, 2018.

Designed by experts

What makes PRODYE so interesting for the denim sector is that it is based on well-thought-out components. One of these innovative elements is the Double Vario dyebath, which operates on the basis of a well-thought-out cross-flow system for perfect dye liquor circulation to give a uniform dyeing result. Additionally, the Quick Oxidation zone operates with temperature-controlled air flow to guarantee uniform dye uptake. Rejects are also reduced and the colour tone of the warp yarn sheet is more uniform than with conventional techniques.

The third important guarantee of success is the PROSIZE® sizing machine, which is equipped with the VSB and HSB size boxes. “These size application systems are becoming more and more popular, since they offer numerous advantages,” says Dieter Gager, the Sales Director. The PROSIZE uses up to 10-percent less size than similar conventional systems on the market. Uniformity is improved and less fiber dust is produced, which improves weaving efficiency. It is ergonomically designed and provides greater process transparency. With an operating rate of up to 180 m/min, it is extremely fast and can also be used flexibly. The yarn sizing range, which depends on the number of yarns and the yarn count, may be up to 20-percent higher than on conventional sizing machines. The working width is 3,200 millimeter maximum. Another advantage of the PROSIZE is that it reduces the number of rejects, because stoppage marks caused by over-sizing are greatly reduced, even when the machine is stopped for long periods.

Posted January 30, 2018

Source: Karl Mayer  at  

BRÜCKNER Sets The Course For The Future

LEONBERG, Germany — February 5, 2018 — Due to the strong demand for BRÜCKNER lines in the last years, an enlargement of the production capacity was indispensable for the German technology supplier. There were no possibilities for expansion at the previous production site in Tittmoning (Bavaria), so that the company came to the decision to build a completely new site near Tittmoning, at a distance of a few kilometers from the previous site. The company management never even thought of moving the production abroad since by doing so the company would lose invaluable employees and thus decades of experience and know-how. The ground breaking in September 2016 was followed by a one-year construction period. In November 2017 Brückner began step by step to move the production to the new production site. In spring 2018 the moving will be terminated.

The new plant comprises 25,000 square meters of construction hall area and is provided with the latest production technology. Since this is a completely new building, all optimization potentials regarding material flow and work place design could be used. The increasing sizes and weights of the machinery components were considered in the selection of the height of the hall and the type of the installed crane systems. Thus, crane systems for the lifting of weights up to 20 tons and crane hooks in a height of 12 meters are available for the final assembly.

The increasing sales success during the last years and the systematic expansion of Brückner’s nonwovens sector had a significant influence on the decision to build this new site. In 2017, Brückner sold in the TECHNO-LINE NONWOVENS product line several lines for the production of geo-nonwovens, light nonwovens consolidated with bonding agents for the medical sector, voluminous thermo-fusioned filler nonwovens for the furniture industry and thermo-fusion ovens for ADL, topsheet and backsheet for the hygienics industry.

Particularly in the field of hygienic nonwovens, a trend shows towards products of a better quality with a smoother hand and of more uniform texture. With the development of a new generation of air-through oven, Brückner created the preconditions to provide customers all over the world with the technology to produce these high quality end products. The successful sales of the new oven generation SUPRA-FLOW BA to renowned nonwovens producers all over the world confirms once again the innovation power of Brückner. Particular attention was given to a gentle transport of the not yet bonded web, a particularly uniform air flow through the web as well as a constant temperature distribution across the complete working width. Important findings from very different thermal treatment systems of related BRÜCKNER product lines could be integrated into the construction design.

The new oven type is characterized among other advantages by the following constructive features:

  • gentle fabric transport;
  • minimum thermal energy required;
  • high flow uniformity;
  • constant temperature distribution across the working width;
  • best possible accessibility of the oven chambers;
  • easy to maintain;
  • flow-optimized air circulation;
  • use of belts with special coating with good detaching characteristics;
  • working widths of up to 4200 mm in the standard design; and
  • production speeds up to 200 m/min.

The continuously increasing number of inquiries for this new type of oven shows that the extensive development efforts were definitely justified and that the new belt oven corresponds absolutely to the market requirements.

Brückner’s nonwovens experts will with great pleasure present in a personal meeting the benefits of the SUPRA-FLOW BA air-through oven in detail to interested customers.

Posted February 5, 2018

Source: Brückner        at 

KARL MAYER’s denim business is booming

In the black with an evergreen in blue

Jeans are, and will continue to be, a top fashion trend, and its denim business is extremely lucrative for KARL MAYER. With its Centre of Excellence for the denim sector, KARL MAYER ROTAL, this global player can offer one-stop solutions for slasher and rope dyeing.

Compared to conventional machines available on the market, the PRODYE-S and PRODYE-R indigo dyeing machines from this Italian subsidiary consume less water, produce less waste and enable deeper, brighter indigo shades to be produced. The dye add-on as a percentage of the total yarn weight is 5.5 % maximum. This warp preparation equipment is also highly productive. The PRODYE-S can double output when processing lightweight denim. The market has been extremely impressed by the performance offered by KARL MAYER ROTAL’s indigo dyeing machines. Demand has been increasing continuously since 2015, and has been especially high this year. Turkey, in particular, has placed a large number of orders.

A large number of orders was placed in 2017

Turkey is a lucrative market for KARL MAYER ROTAL. Many large denim producers there are already working with the PRODYE-S machine and have placed follow-up orders this year. Follow-up orders have also been received from companies in Mexico. Machines have also been delivered to companies that are new to this technology – in Turkey and Iran as well. Turkish companies are also contributing to the success of the PRODYE-R. This rope dyeing machine was only delivered in May 2017. It was sent to Algeria as part of a large project, under the auspices of TAYAL, a joint venture involving the participation of the Turkish company, Taypa. Turkey invested in another PRODYE-R machine in the autumn of this year.

KARL MAYER ROTAL invited any specialists who were interested to travel to Vietnam to see a practical demonstration of its indigo dyeing machine. One customer, who has been working with the PRODYE-S since February 2017, made his company available for the open-house show, and reported on his experiences. The event was attended by a small yet highly qualified group of people. The visitors came mainly from the host country, but also from Hong Kong, Indonesia and China. The next opportunity to see KARL MAYER ROTAL’s DENIM machines will be at the ITM International Textile Machinery Exhibition in Istanbul, which will take place from 14 to 17 April 2018.

Designed by experts

What makes PRODYE so interesting for the denim sector is that it is based on well-thought-out components. One of these innovative elements is the Double Vario dyebath, which operates on the basis of a well-thought-out cross-flow system for perfect dye liquor circulation to give a uniform dyeing result. Additionally, the Quick Oxidation zone operates with temperature-controlled air flow to guarantee uniform dye uptake. Rejects are also reduced and the colour tone of the warp yarn sheet is more uniform than with conventional techniques.

The third important guarantee of success is the PROSIZE® sizing machine, which is equipped with the VSB and HSB size boxes. “These size application systems are becoming more and more popular, since they offer numerous advantages,” says Dieter Gager, the Sales Director. The PROSIZE® uses up to 10% less size than similar conventional systems on the market. Uniformity is improved and less fibre dust is produced, which improves weaving efficiency. It is ergonomically designed and provides greater process transparency. With an operating rate of up to 180 m/min, it is extremely fast and can also be used flexibly. The yarn sizing range, which depends on the number of yarns and the yarn count, may be up to 20% higher than on conventional sizing machines. The working width is 3,200 mm maximum. Another advantage of the PROSIZE® is that it reduces the number of rejects, because stoppage marks caused by over-sizing are greatly reduced, even when the machine is stopped for long periods.

A high demand for the LACE.EXPRESS has led to the development of the new OJ 83/1 B

Success breeds success

KARL MAYER’s Lace.Express lace raschel machine is keeping the promise made by its name, i.e. this new range has an impressive level of productivity and is quickly becoming established on the market. Encouraged by the first representative of the Lace.Express range, KARL MAYER has now extended this range of machines, for which there is a high demand. The latest edition of the Lace.Express range is the OJ 83/1 B.

KARL MAYER’s Lace.Express lace raschel machine is keeping the promise made by its name, i.e. this new range has an impressive level of productivity and is quickly becoming established on the market. The first representative of this machine series, the OJ 59/1 B, was only premiered at the end of 2016 and orders are already running into the high double-digit range. Up to 20 machines are leaving KARL MAYER’s assembly line for a number of projects. The types of buyers are extremely varied. Companies new to the technology of KARL MAYER’s electronic raschel machines are among its clients, as well as long-term partners, who are placing follow-up orders, and companies who are changing over from using machines produced by other manufacturers.

Encouraged by the first representative of the Lace.Express range, KARL MAYER has now extended this range of machines, for which there is a high demand. The new machine is giving customers the opportunity to use the technology of this innovative machine series to produce fabrics for outwear and underwear. This dual expansion was triggered by feedback on the OJ 59/1 B from the market.

Same speed, more patterns

The latest edition of the Lace.Express range is the OJ 83/1 B. It is available in gauges E 18 and E 24, has a working width of 210″, and can reach the same high operating speed as the OJ 59/1 B. However, increasing the number of guide bars compared to the first Lace.Express machine means that more patterns can now be produced. In particular, being able to work picot patterns also makes the new machine interesting for producers of tapes and ribbons for intimate apparel. Stylish outerwear fashions, as well as sophisticated lingerie, can also be produced from the lace goods manufactured on the OJ 83/1 B. By using thick yarns, the new machine can also work structured patterns. Up to 32 pattern bars are available for processing yarns to produce a wide range of designs.

Unbeatable productivity and profitability

The new lace raschel machine is far superior compared to reference machines having a large number of guide bars on the market. Extensive experience gained with using the machine in practice has shown that the output of the OJ 83/1 B is 44% higher and the figure is similar for profitability when producing apparel lace. The OJ 59/1 B already has an excellent cost:benefit ratio. This has been proven on the market and also applied to the OJ 83/1 B.

This new machine from KARL MAYER is also efficient in terms of its energy consumption. The OJ 83/1 B consumes up to 40 % less energy compared to other reference machines on the market. KARL MAYER’s LEO® system is behind this considerable reduction. The basic design takes into account the technical concepts of tribology, the pneumatic systems, and the drives for yarn feed, fabric take-down and batching. By optimising the construction, energy losses can be minimised and energy can be utilised more efficiently.

In terms of its ergonomic features, the new OJ 83/1 B also benefits from the high standards typical of KARL MAYER – in particular, the movable Operator Interface, hinged stitch comb bar, easy access to all the drives, a new creel design and an optional, integrated LED lighting system make working a pleasure and operating the machine is mere child’s play.

The market is impressed by the exceptional performance of the OJ 83/1 B. It was only released for sale in October 2017, but the first orders have already been taken – with delivery scheduled for 2018. This new machine was constantly surrounded by people during its first public unveiling at an in-house show held at KARL MAYER (CHINA) from 23 to 25 November. “Shortly after the launch, our sales organisation took orders from both inside and outside China, which is an important indication that the success we have enjoyed so far will continue,” says Jan Hippich, the Head of Product Portfolio at KARL MAYER.

Technical details

The new OJ 83/1 B belongs to the LACE.EXPRESS machine series, which complements KARL MAYER’s repertoire of lace machines, which includes the JACQUARDTRONIC® LACE, TEXTRONIC® LACE, MULTIBAR LACE and LEISUREE.FASHION machines.

The new machine has 14 shog rows, of which 10 are fitted with eight pattern bars for creating the fabric design. The technical features also include the jacquard system of the usual high quality. The fabric produced is wound up by free-standing batcher no. 51. The creel configuration is made up of creels with 16 tiers to create the optimum conditions for loading the bobbins. The machine is available with 30 repeats as standard.

KARL MAYER Technische Textilien successfully takes part in FUTURE – a project for combining steel and carbon fibres in multiaxial textiles

The blend makes it all possible

Carbon-fibre-reinforced plastics (CFPs) represent a beacon of hope for the lightweight construction sector. These extensively used composite materials deliver excellent mechanical properties and, at the same time, have a low density, but their electrical conductivity is poor. This is a particular disadvantage for their use in aircraft. Protection against lightning is an absolute necessity for this demanding application at high altitudes. The CFP structures used until now have been combined with woven grid constructions made from copper to produce laminates that will guarantee safe flying, even in bad weather. But this solution is extremely complex, and the aim of this project was to find a simpler technique. The research project, which was publicly funded by the BMBF, was entitled “Funktionale Textilien und reproduzierbare Ergebnisse” (Functional Textiles and Reproducible Results) – FUTURE for short, under the direction of the project sponsor, Jülich.

It lasted from October 2014 to the end of September 2017 and was carried out by KARL MAYER Technische Textilien GmbH (Technical Textiles) in Naila. The partners in the project were the Institut für Verbundwerkstoffe, IVW (Institute for Composite Materials) in Kaiserslautern, AIRBUS in Munich and Quickstep in Ottobrunn.

The aim of the project – to develop a hybrid solution

The project involved developing carbon-steel-fibre hybrid structures as a replacement for the labour-intensive process for producing laminates. The first stage involved ideally producing spread tape-hybrid structures and bonding them in a second stage on the COP MAX 5 using warp knitting technology. The plan for the project, which was drawn up by KARL MAYER Technische Textilien, also involved the study of multiaxial textiles with 0° warp yarns made from steel. The steel material had to be combined with 0°/90° and +/- 45° carbon layers on the COP MAX 5 and processed into hybrid multiaxial textiles using a tricot construction. On the basis of the composite structures, the project partners hoped to achieve a similar or better protection from lightning in the finished components, and subsequently to guarantee a much better ductile behaviour in the event of a lightning strike, i.e. improved impact characteristics compared to the previous laminated system.

Successful preliminary work as a basis for subsequent work on the project

Implementing the project was definitely a worthwhile exercise for KARL MAYER Technische Textilien. Fundamental textile/technical facts were established during the investigations using both theoretical and practical principles.

The effectiveness of KARL MAYER’s spreading principle during spreading of the steel fibres and carbon-steel-fibre hybrids was again confirmed unequivocally. By using online spreading technology, which involves the use of TC 54 creels developed by KARL MAYER Technische Textilien, it was possible to lay and bond high-quality single-layered hybrid angled structures on the COP MAX 5.

The high quality of the textiles was confirmed yet again by carrying out basic tests. KARL MAYER’s specialists compared online and offline production on the COP MAX 5 in detail in order to produce products with first-class characteristics for use in the aerospace sector. At a layer weight of 110 g/m², the online-spread carbon multiaxial textiles had a better channel structure, homogeneity, thickness uniformity and appearance. The reason for this is that the previous tape winding and unwinding process, which was a source of quality problems, can now be dispensed with. Carbon fibre tows with the following characteristics were used in the tests and comparisons: TORAYCA® T 700S, 12K, sizing type 50C and 60E.

On the basis of the results of the experiments, carbon multiaxial textiles with a structure of 0°/90° and +/- 45° were produced and combined with steel rovings as the warp yarns. The steel-fibre-carbon hybrids produced were processed at the IVW in test samples and yielded some fundamental results, which would be useful in further scientific investigations.

Postscript:

“The FE project, on which this article is based, was carried out under the auspices of the Bundesministerium für Bildung und Forschung (Federal Ministry of Education and Research), no. 03X3042B. The author is responsible for the contents of this publication.”