Since 2007, KARL MAYER's :successful product strategy has been to offer high-tech machines for producing more upmarket products, as well as basic versions for manufacturing cheaper products, which puts this traditional company in an ideal situation to cater for all the different sectors of the market.
This twin product line strategy was unveiled for the first time at ITMA in Munich and was applied to the company's tricot machines. The new TM series, which was developed expressly for this strategy, soon became a firm favorite among customers, and has been effectively complementing KARL MAYER's range of tricot machines ever since.
Technical progress in the warp knitting sector bears all the hallmarks of KARL MAYER. With their increased performance, quality and flexibility, the machines produced by this traditional manufacturer have enjoyed considerable success for many decades all over the world. One of the most important chapters in the company’s history was the integration of carbon-fibre-reinforced plastic (CFP) bars into the machines and modifying the design of the machines accordingly. These high-precision composite components are up to 25 % lighter than the conventional version. They are also more rigid, thus enabling speeds to be increased considerably, for a simultaneous optimisation of the machine availability. The high temperature stability of the CFP materials has enabled the window for problem-free machine operation to be increased from +/- 2 ºC to +/- 5 ºC, and subsequently even to +/- 7 ºC.
The company’s tricot machines were the first to profit from this lightweight construction technology, and have been available with CFP bars since the ITMA fair in Munich in 2007. Once the gradual changeover of this machine series had been completed, work began on adapting the raschel machines. The first machine with CFP components, the RSE 4-1, will appear on the market at the beginning of April 2010.
With its revamped bar and shaft concept, KARL MAYER has optimised the use of this technology and made it easier to operate.
The developers and engineers have recently come up with a solution which has made the high temperature stability, which is now a standard feature of this new warp knitting technology, to be achieved more easily and efficiently. The lynchpin of this increased efficiency was to substitute the old continuous, tempered shafts for controlling the bars with components that have been divided up into high-precision segments. The shaft is divided into segments according to specific machine parameters, and it is no longer necessary to carry out the heating-up stage that was previously required following a machine stoppage. This has reduced the time-consuming heating-up phase, cut down on energy costs, and dispensed with the need to specifically adjust components during the start-up phase.
In addition to the short starting-up times, machines equipped with second generation CFP technology are more stable to ambient temperatures when operating, and thus guarantee a high gauge accuracy. Even when producing fine fabrics and at large working widths, the production machine runs smoothly at top speed to produce top-quality textiles.
The changeover of the high-speed knitting machines to second generation CFP components will start again soon, and will be carried out gradually over the course of the year.
A patent has been applied for to protect this innovative system.
Opening cases Take care not to damage the thread with any sharp instrument that may be used to cut open the carton.
Once opened - pull the plastic bag liner over the sides of the case to prevent contact of the spandex liner, which could disturb the wind and affect the performance in knitting.
Although not an absolute requirement, some users of spandex fibers prefer to open cartons in the same environment in which it will be processed for a period of 24 hours prior to its use. Removal of packages Remove the returnable black separator tray by grasping the handle holds and pulling straight up to prevent contact with the layer of spandex packages below.
Grasp the spandex package by positioning the thumb (not thumb nail) in the top center of the package with one or more of the remaining fingers placed inside the tube, again avoid contact with the edges or shoulders of the package.
Handle only one package at a time. Stacking, cradling or otherwise transporting more than one tube or cone at a time dramatically increases the likelihood that the package may be bumped and the wind may be disturbed causing running tension variation and breaks.
The use of a tray, pin truck or other suitable carrier is recommended for handling multiple packages by one operator. Inspection Briefly inspect the package for "fall-overs" (spandex ends fallen off the edge of the package). If "fall-overs" are found, clear by lightly pinching the top center of the package with the thumb and forefinger (do not pinch with fingernails) and pulling the spandex over the edge of the package until a single end remains, or gently roll the "fall-off" ends back onto the surface of the package using the fleshy part of your palm, which must be free of
callouses or skin burns.
Since 2007, KARL MAYER's :successful product strategy has been to offer high-tech machines for producing more upmarket products, as well as basic versions for manufacturing cheaper products, which puts this traditional company in an ideal situation to cater for all the different sectors of the market. 
