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  

NEW PAGE WEB TOYOTA TEXTILES

Our Challenging History

Pioneering the Textile Industry Through Technology and Imagination

Over a Century of History

Founder Sakichi Toyoda invented a circular loom dubbed the “dream loom” in 1906. As he noted, “This makes possible quiet weaving of extremely wide fabrics without wasted power.”

 

Today, as it has since its inception, Toyota Industries Corporation continues the tradition of these revolutionary concepts and viewpoints ahead of their time as it has overcome numerous obstacles and rolled out wide-ranging operations that include automobiles, material-handling equipment, compressors, electronics, and more.

Sakichi held that “dedication to technology and imagination is the source of world trends.” The spirit embodied by these words has taken firm root in the textile-machinery operations that constitute the origin of the Toyota Group. Now and into the future, we will continue to evolve beyond equipment development to contribute to the growth of the textile machinery business through automation of factory systems, network-based operation-control systems, and more.

In 1924, Sakichi Toyoda succeeded with his ultimate target to develop an automatic loom with shuttle change. This first and top-performance loom is his great invention resulting from his long-range research and development.
As he began inventing automatic looms in 1902, Sakichi invented an automatic shuttle change motion and other automated devices, including protectors and safety devices. His deep belief as an inventor was that anything created by man should have to pass an extensive test to prove value and consistency. Thoroughly confirming the practicality of all processes from spinning to weaving enabled him to put an automatic loom with non-stop shuttle change on the market, revealing to the world a loom crafted perfectly in his vision. This automatic loom is the cornerstone of the Toyota group and it is the culmination of Sakichi’s invention which pioneered the industrial modernization of Japan. This automatic loom is the culmination of his inventions, which forms not only the base of our Toyota Group but is also the pioneering machine of Japanese moderm industry.

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A Trusted 150,000 Units Installed.
Toyota continues to enjoy the No.1 markets share
worldwide for air jet looms. (from year 1997 to 2016 )

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.