Wednesday, 26 October 2011

Warp Knitting | Tricot Machines (Karl Mayer) at Glance

Two guide bars tricot machine with high performance from Karl Mayer for universal application, from light tulles to heavy raised velour .This model is also suitable for very low stitch densities and coarse gauges as well.

Below are some of applications that can be produced in the HKS 2 tricot machine.
  • Mosquito nets.
  • All kind of tulle fabrics.
  • Sport wear articles.
  • Shoe Fabrics.
  • Ground fabrics for printing / advertising media.
  • Coating substrates.
  • Laminating backings.
HKS 2-3 / HKS 2-3 E
High-performance tricot machines with two guide bars from Karl Mayer to produce plain rigid  fabrics and elastic fabric as well by fitting the elastic device (tube deviation) for the second guide bar as a replacement tension bar which is used to produce un-elastic fabric,The letter (E) on HKS 2-3 E signify that machine equipped with Elastic device to produce elastic fabrics.

Tuesday, 24 August 2010

Warp Knitting | Caculation of Residual Yarn sheet on Warp Beam

In some cases on warp knitting fabric production practically ,we need to cut and replace the warp beam before the warp beams are finish and some yarn still remain wound up on the warp beams.The remain yarn sheet /residual yarn sheet on warp beam will be keep for next production order,for example due  a sudden change an order of fabric article or during the warping process warped yarn to much in the length or just for make a fabric samples or due another reason,whatever…

In this case we need to tape a yarn sheet on the warp beam,cut them  off and remove,however  we need  also to calculate  how many meters or kilo grams a yarn sheet remain on the warp beam for future used.Following are the formula to calculate the remain yarn sheet on warp beam for Warp Knitting.

First of all we need to know and to determine the current winding or the actual winding on warp beam,as follows ;

Thursday, 12 August 2010

Warp Knitting | Metallic Yarn Used on Warp Knitting Fabric

Metallic yarns are by and large made from strips of a synthetic film, such as polyester, coated with metallic particles. In one more method, aluminum foil strips are sandwiched amid layers of film. Metallic yarns may also be made by twisting a strip of metal around a natural or man-made core yarn, producing a metal surface. It is made of thin film and supported by nylon or polyester or rayon yarn according to the type of yarn.
Metallic yarns start as rolls of films or laminations 30" or wider. These wide rolls are slit into narrow rolls 2" to 5" wide. These narrow rolls are gang slit across their whole width to micro widths from 1/128" (.0078") and wider and then taken up on plastic spools for shipment to textile mills. There is a rainbow of colors available from red, blue, green, etc. to gold and silver. Brilliant, reflective colors which add decorative patterns to fabrics.
Many metallic yarns  knitted into fashionable Raschel and Jacquard fabrics . For added variety, metallic yarns are twisted with other fibers such as wool, nylon, cotton and synthetic blends to construct yarns which add novelty effects to the end cloth or trim. They create all fabrics more eye-catching by adding sparkle.
At one time or another, metallic yarns have been used in just about every variety of textiles. Metallic Yarn is used in manufacturing knitting wears, knit and woven fabrics, embroideries, labels etc. Some end uses have been in automotive fabrics, television front fabrics, bath towels and face cloths, clerical vestments, bathing suits, hosiery, upholstery, hat bands, etc. Also in theatrical clothing, theatre back drops, doll clothing, banners and uniforms.

Wednesday, 11 August 2010

Warp Knitting | Active Pattern beam drive for high speed lace machines developed by Karl Mayer

ActivePattern_yarn_feed Karl Mayer company has developed an active pattern beam drive for its high-speed lace machines which consists of a tension controlled yarn delivery system.This innovative control principle has already been used in practise by customers operating lace raschel machines. The system consist of a yarn-tension controlled yarn delivery system and can be use with all pattern beams.It is based on the tried and tested servo system,which has been successfully used for many years for driving the string bars.A new and improved version is currently being tested.The changes that are incorporated in this improved version relate to use of a new type of motor and replacing the existing friction control system with toothed wheel for power transmission.
Passive pattern yarn feed
In passive pattern yarn feed, the pattern beams run on ball bearings and are driven by the yarn let-off system at the knitting point, a solution which Karl Mayer says has its limitations at high machine speeds. Despite the use of balancing units, the physically induced mass inertia of the longitudinal shafts, together with the yarn warps which are arranged in a row, is said to be so great that it can cause 

Saturday, 24 July 2010

Warp Knitting | Powernet Structure for Lingerie

Karl Mayer Pattern No. 148/09
(Design No .S-4002812)
From a high performance Raschel machine with four ground guide bars and CFRP bars.
Source : KWP 1/2010
This power-net structure for lingerie articles cuts a fine figure.In spite of its puristic appearance and cool touch,this is unsophisticated fabric unveil its true qualities when its comes to such functional features as e.g holding,supporting,shaping and moulding.This stretch textile with specific elastic smoothes out unflattering curves,without restricting or even constricting one’s movements.Not only can the body stylist breathe a sigh of relief but the body can also take deep breath.The filigree mesh openings ensure a sufficient heat and moisture balance.
Pattern (finished fabric)
Stitch courses : 
Weight :
Finished fabric:
84/cm (set: 50/cm)
119 g/m
86 % of the knitting width
Finishing : Relaxation,washing,drying,setting,bleaching,optical brightening,stentering
Machine type :
Machine gauge :
Number of guide bars:
Machine width :
Number of pattern disks :
Machine speed :
Production (finished fabric) :
E 32 (needles / 25.4 mm=1”)
170” (431 cm)
4 ( 24 M )
2.500  min-1  
17.8 running m/h (7.9 kg/h)

Bars Material specification % of material Run-in rack
GB 1 dtex 44 f 12 polyamide 6 (Nylstar ®),deep dull,flat,round 37.7 % 800 mm / rack
GB 2 dtex 44 f 12 polyamide 6 (Nylstar ®),deep dull,flat,round 37.7 % 800 mm / rack
GB 3 dtex 320 elastane (Dorlanstan ®),V 550,elongation 25 % 12.3 % 45 mm / rack
GB 4 dtex 320 elastane (Dorlanstan ®),V 550,elongation 25 % 12.3 % 45 mm / rack
Bars Lapping Threading
GB 1 1-0 / 1-2 / 2-1 / 2-3 / 2-1 / 1-2 // 1 out ,1 in
GB 2 2-3 / 2-1 / 1-2 / 1-0 / 1-2 / 2-1 // 1 out ,1 in
GB 3 ( 0-0 / 1-1 ) x 3 // 1 out ,1 in
GB 4 ( 1-1 / 0-0 ) x 3 // 1 out ,1 in

Sunday, 18 July 2010

KARL MAYER shows its latest innovations in warp knitting machines at ITMA ASIA+CITME 2010

2010Lightweight components and a twin product line strategy – optimised concepts to suit every requirement - ITMA ASIA+CITME 2010, held 22 to 26 June 2010 in Shanghai

KARL MAYER’s successful policy for its warp knitting machines is based on lightweight constructions and a twin product line strategy – an arrangement that is specifically designed to meet the requirements of the market. The machines equipped with CFRP (carbon-fibre-reinforced plastic) components offer a unique performance profile, and the strategy of making both basic as well as high-tech machines available gives the company greater access to a broader client base.
The results of the company’s efforts to constantly optimise its products were on show at ITMA ASIA+CITME 2010, where KARL MAYER was displaying the first raschel machine equipped with CFRP components and a high-speed tricot machine, which is already benefiting from the advantages of 2nd generation of CFRP technology.
Other highlights on KARL MAYER’s stand at ASIA+CITME 2010 were a machine in the Seamless Smart range, a JL 59/1B, both in exceptionally high machine gauges, and the KAMCOS® Explorer for producing a basic MDE system.
The latest innovations in double-bar raschel machines were also on display at an in-house show held at KARL MAYER’s subsidiary in Wujin in the run-up to the fair and also during the exhibition itself. This event was held from 16 to 21 June and, as well as showing a new, basic HighDistance® machine, was also demonstrating the new RD 6/1-12.
The first raschel machine equipped with CFRP components
RSE 4-1 with CFRPThe new RSE 4-1 is the first machine in its series to feature lightweight technology. The package of optimised features includes the use of CFRP components in all the bars, and solutions for improving the stability to lateral distortion in the needle zone. The basic design as well as specific details of the machine were also adapted to suit the higher dynamics.
The result of changing over the RSE 4-1 to incorporate these lightweight, stable, fibre-reinforced plastic components is that the temperature window for reliable, trouble-free operation has been extended from +/- 2 °C to +/- 7 °C, and the weight of the bars has been reduced by as much as 25 % - and this has resulted in an exceptionally high productivity rate.
Throughout the exhibition, the RSE 4-1 (170", E 32) with its high speed of up to 2,600 min-1 caused quite a stir. The high-performance raschel machine is already one of the best-selling machines in KARL MAYER’s product range, and was in great demand during the fair.