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.

No.1Global Share

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 hot outfit for cold days – KARL MAYER

Knitted bolero with a lace look, made from a fabric produced on an HKS 4-M EL

Winter does not always have to mean polo-neck jumpers, chunky knits and grey-on-grey colours. Even on cold days, women can be brave enough to wear transparent fabrics and show a little skin. The ensemble shown on this page is a stylish example of this. This delicate bolero and the light and airy little tulle skirt are reminiscent of beautiful figure skating fashions and are an attractive contrast to fur – the classic winter warmer. 

A real eye-catching feature of the outfit is the cropped top, which is made from a feather-light fabric with a lace look, produced on a high-speed tricot machine. An HKS 4-M EL in a gauge of E 28 was used to produce it. The machine’s EL control facility, the clever yarn threading arrangement, and the sophisticated combination of yarns produce a lace-look fabric featuring a variety of designs, i.e. mesh structures with large openings and dense areas with superimposed scalloped patterns create an alternating striped design. The interplay between the open-work and the dense constructions is produced by the yarns processed in ground guide bars GB 3 and GB 4. A filet threading arrangement and a fully threaded arrangement alternate in sequence. GB 2 and GB 3 work the pattern in the dense areas.

 

Matt/shiny effects bring a touch of extravagance to the graphic look. The shimmering effect is produced by processing monofilament yarns having a trilobal cross-section in the filigree ground, which resembles an embroidery ground. The superimposed design is made from textured polyester multifilament yarns having a large number of filaments – a choice of yarns that enables the design to contrast effectively with the ground.

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.”

Innovative solutions relating to the topic of reinforcement layer fabrics

KARL MAYER Technische Textilien at the JEC World, to be held from 6. to 8. March 2018 in Paris, Hall 5, Stand Q58

The company KARL MAYER Technische Textilien GmbH, a competent and committed partner of the composite industry, will also be exhibiting at the upcoming JEC World to take place from 6. to 8. March 2018 in Paris. This machine manufacturer invites the trade fair visitors to come and see its Stand Q58, Hall 5, in Paris Nord Villepinte Exhibition Center. Here the company will be displaying its high-performance composite machines, namely: the COP MAX 4 as a flexible allround model for producing multilayered, multi-axial structures with angles ranging between maximum +20° and -20° and the COP MAX 5 especially designed for processing carbon fibers. The COP MAX 5 can manufacture layer fabrics with a very low weight per unit area; the machine works either with an on-line or an off-line feeding system of the fiber material. For the spreading of the fiber tapes for the off-line version, KARL MAYER Technische Textilien can offer the fiber spreading unit UD 700. Information on the high-performance machines is available as video presentation, print media to read, and also during discussions with the KARL MAYER specialists. One main focus will be on the topic of glass layers with defined carbon fiber reinforcements. The tailor-made reinforcement textiles are produced on multi-axial machines with filler thread shogging device during the so-called „VARIOLAYING“ procedure.

KARL MAYER CONFERENCE 2018

Successful conference entitled „Additive manufacturing for the textile industry“ held at KARL MAYER in Obertshausen, on 11. January 2018

The organizer of this event was the Textile Research Institute Thüringen-Vogtland e.V. (TITV), the cooperation partner was KARL MAYER. With this meeting the two innovation drivers of the textile industry have really hit the mark. „We want to create the exchange between the two worlds, namely between the additive manufacture as a young discipline of production and the textile sector as an industrial branch with a long tradition“, explained KARL MAYER Product Manager, Michael Kieren, in the run-up to this event. Together with his team, he organized a programme that attracted roughly 100 specialists from different fields to Obertshausen. The invited guests included manufacturers of textiles for the automotive, sports and medical sectors, finishing professionals and yarn manufacturers as well as experts from science and research. The interest in the meeting exceeded all expectations. „I am very surprised by the high response to our conference and by the wide range of different areas from which our guests come. Both aspects show the importance of this topic, and the significance of events of this kind“, said Arno Gärtner, KARL MAYER’s CEO, during the conference. Dr. Uwe Möhring, Managing Director of TITV, also expressed his satisfaction with the course of the meeting. „I think it’s great that so many people have come , and that so many different discussions arise, especially in view of the high event density at the beginning of the year. The contributions with real topics but also the size and mix of the audience encourage a successful exchange.“

The agenda included lectures held by 3D-printer manufacturers as well as by companies that have already been working with additive manufacturing methods; they informed about their experiences with various possibilities but also about still existing limitations. Two experts presented first combinations of textile and 3D-print. Besides, a service provider in this business also took the floor: Tatcraft from Frankfurt presented with Maker Space its capacities for 3D-print, wood working, water jet cutting and other technologies to experiment and explore different possibilities without major investments.

LONDON CALLING!- MAHLO 2018

Trainee Emma Thaler visits Britain’s capital for further education

Expanding your knowledge, improving your English language skills, and thereby discovering one of the most exciting European metropolises? What an opportunity! One that our commercial apprentice Emma Thaler seized by taking part in an advanced training at the Central College London that was organized by the vocational school Kelheim. For three weeks she learned new things about the United Kingdom’s economy, culture and language. After class, Emma had enough time to discover the British capital.
Mahlo supported her project, because the machine builder trusts the words of American politician Benjamin Franklin: “An investment in knowledge always pays the best interest.”

Welcome to the UK!

One of London’s most famous sight: the Tower Bridge

On 24 November 2017, my three week journey to London started. The preceding days, when packing my bag, I was pretty nervous and excited. I was curious what would lie ahead and what kind of people I would meet. I also have never been away from home for such a long time. But as soon as a arrived at the Munich airport and boarded the plane, all nerves were gone and I just wanted to get started.

Just after we had arrived in London, we were introduced to our host families. I was extremely lucky with mine. Hardly have I met people that nice and lovable. That’s why I felt at home from the first minute on.

The following days, the other students – all from the Kelheim and Regensburg area – and I had just one thing on our list until our class began: lots and lots of sightseeing.  We walked through London all day long and visited many tourist attractions, for example the Tower of London, the Buckingham Palace and Camden Market.  

College Experience

Great view of a great city at The Shard

When the first day at the College came, I was a little bit nervous what to expect, because I have never been to one. My nervousness was unfounded, however: our group consisted of many nice people and our teacher was also friendly. The following days and weeks therefore flew by. Due to our lessons and many interesting study trips, like a boot tour on the Thames to Greenwich or a visit to the court, we have learned a lot about England’s economy, language and culture. Our course also encompassed many presentations and a test.

Every day after class, we had enough time to discover London on our own. We did many funny things like ice skating, visiting the skyscraper The Shard (you have a stunning view of London) or the Winter Wonderland Christmas market and fairground at Hyde Park.

Back home

Emma in front of the Millenium Bridge

When we had to say our good-byes on 15 December at the airport, not one of us really wanted to leave. We had loved to stay a little bit longer but unfortunately that was not possible.

Now, that my journey is over, I can say that the three weeks passed by way to fast. London is a great city with beautiful places and interesting people. I have found many new friends and gathered experiences. For me, the trip was definitely worth it. Not just because I gained new knowledge but first and foremost because I developed myself. I can only advise everyone to seize such an opportunity when offered. And I also thank my employer that he made my extra-curricular training possible.

And I definitely will visit London again!

NUEVO BIOLÓGICO DE WATERNEXT EN MEXICO

Buonasera a tutti,

Venerdi scorso abbiamo consegnato il nuovo biologico in Global Denim.

Il lavoro finito risulta una meraviglia, in quanto a montaggi e risultati di processo.

Con questo lavoro al biologico, possiamo vantare che tutto il trattamento acque di Global Denim e’ stato realizzato da WaterNext, Torre raffreddamento, chimico-fisico, trattamento fanghi, biologico.

Buenas tardes a todos , 

El pasado Viernes hemos entregado el nuevo biologico en GLOBAL DENIM .

El trabajo ha resultado una maravilla , en lo que respecta al montaje y los resultados de proceso. 

Con este trabajo Biologico , podemos estar orgullosos que todo el tratamiento aguas de GLOBAL DENIM ha sido realizado por WATERNEXT , torre de enfriamiento , quimico-fisico , tratamiento de lodos , biologico.

 

Felicidades por un nuevo trabajo bien hecho !!!