Warp Knitting | Multibar raschel machines with a working width of 210" are premiered in India

KARL MAYER unveils its Multibar Lace series in India at one of its customers, Tee Pee Textiles, which is part of Zenith Silk Mills PVT Ltd., in Surat, on 26.05.2014

The ML series of raschel machines is setting the standard in the fashion sector, as well as in the production of traditional garments. With their gauge of E 24, these machines are catering for the continuing trend for light, delicate plain fabrics and lace. In a working width of 210", these best-selling machines from KARL MAYER are a must for producing saris in particular. The first wide-width multibar raschel machine was delivered to India recently – to the warp knitting mill, Tee Pee Textiles, in Surat, in the state of Gujarat. Tee Pee Textiles and KARL MAYER are inviting any company that is interested to the inauguration and demonstration of this new machine on 26 May. KARL MAYER is expecting customers to attend from all over India. The Managing Director, Arno Gärtner, and Oliver Mathews, the Sales Director of the Warp Knitting Business Unit, will welcome the guests.
During the demonstration, the ML machine will be producing two different sari fabrics, each consisting of four panels next to each other in a gauge of E 24.

Highly productive with a width of 210"
The machines in the ML series have an excellent cost:benefit ratio. At a width of 134", they can reach speeds of up to 900min-1, and the machines having a width of 210" are extremely productive, especially when producing sari fabrics – four 50"-wide fabric panels can be produced next to each other simultaneously. The working width of 210" is therefore ideal for producing this traditional Indian style of dress.
In addition to being fast, the multibar raschel machines are also user-friendly, accurate and flexible. The pattern can be changed with very little time and effort. This enables customers to produce even small batches efficiently, and react quickly to changing market trends.
Traditional Indian designs on tulle net – the recipe for success when producing saris
The fabrics produced on the Multibar Lace machines are delicate and more or less open, and feature continuous net grounds. The pattern elements, which are usually floral and decorative, are worked into the ground in sweeping lines to create striking effects. Typical of sari production are simple tulle grounds and, for example, Paisley patterns with sequin embroidery or large decorative flowers and leaves with a folklore look. The panels can be decorated with a narrow, curved border – to produce an attractive hem without the need for any making-up.
Source: Karl Mayer News

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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 2^nd 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
The 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.

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Karl Mayer News | Second generation of CFP components – the second stage of the optimisation programme improves machine availability

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.

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Warp Knitting | KARL MAYER’s RSE 4-1 continues to write history

The first raschel machine equipped with CFRP components will be available on the market in April 2010

 

KARL MAYER’s RSE 4-1 is definitely the fastest four-bar raschel machine in the world, and will soon have even more accolades heaped upon it. It will be launched onto the market in April 2010 as the most reliable machine in its series. It will set new speed standards and operate with precision accuracy - completely independently of the climatic conditions.
The speed has been increased by integrating innovative CFRP components into the machine construction, which has been specially adapted to handle these components. This is a technological quantum leap forward, which has already enabled some of the other high-speed warp knitting machines produced by KARL MAYER to be operated extremely successfully by the company’s clients.
The RSE 4-1 is the first raschel machine to be equipped with the CFRP components. All the bars on this highly efficient machine for processing stretch fabrics have been manufactured from this lightweight, stable material. The entire machine, from the needles to the basic machine design, has been modified to cope with the resulting increase in speed.
The changes that have been made to the needles have focused on increasing the resistance to lateral distortion, whereas aspects of the basic machine design were optimized specifically in terms of the machine dynamics. The modifications that were made to improve the stability, both of the bars as well as the basic machine, were made by carrying out detailed and extensive calculations using tried-and-tested procedures, such as the finite element method and multi-body simulation systems. Nothing was left to chance and this can be seen quite clearly from the results of these technical improvements.
The weight of the CFRP bars has been decreased by as much as 25% compared with the conventional type, whilst the rigidity has been increased. This has opened up more scope for setting the maximum achievable speed. Above all, however, the use of CFRP materials results in an exceptional temperature stability during production. The temperature window for problem-free machine running has been extended from +/- 2ºC to +/- 7ºC. Extending this tolerance range has minimized any loss in efficiency caused by having to adjust the needle tool as a function of the climatic conditions, or to reduce the speed following a machine stoppage. The result is that the machine availability of the RSE 4-1 is higher than ever before, which has increased the total overall performance of this high-tech production machine.

 

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Karl Mayer News

KARL MAYER at Techtextil India 2009, 10.10.-12.10.2009 in Mumbai, Bombay Exhibition Centre hall 1, booth E13 /15 

KARL MAYER will appear at this year's Techtextil India with its subsidiary KARL MAYER Malimo and will thus focus on machines for the production of composites. The nonwovens from KARL MAYER multiaxial machines (Fig.) are currently being used in particular as glass reinforcements in the wind power sector and boat construction, where the demand is high. However, geotextiles from RS 3 MSUS-V weft-insertion raschel machines and textile materials from the RS 2 (3) MSUS machine which are used as advertising media have become best sellers on the market. The members of the KARL MAYER fair team are therefore really looking forward to the forthcoming event. They are looking forward to seeing all the important visitors from India and the neighbouring states, have various projects for further negotiations in their locker, and hope to make the company even better known than before. This is a goal which the exhibits from the KARL MAYER business unit – warp-knitting machines -will enable the company to reach. Here the range exhibited extends from packaging, shading and fishing nets from RS 4 with ISO, RS 4 FN and RDS 11 raschel machines , via mosquito nets from HKS 2 machines to warp-knitted spacer fabrics for use in shoes, mattresses and seats, for example. The KARL MAYER exhibition schedule will be completed by warp preparation products for the technical textiles sector.

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Karl Mayer's | Warp Knitting | HKS 4 (EL) | with carbon-fibre-reinforced plastic | (CFRP)

Machine Review

The hallmarks of the HKS 4 (EL), which has proved itself so successfully
for so long, are its speed and flexibility. The optional use
of electronic guide bar control in particular has made this four-bar, high-speed tricot machine an invaluable production machine for efficiently producing even small production batches and for dealing with the short cycles involved with developing new products.
Another optional feature from among its many design features is a pile mechanism for producing high quality plush fabrics.
The machine can be changed over easily and quickly to produce loop-pile fabrics, since the compound sinker does not have to be changed. This flexible design concept has now been topped off by a system that is intended to considerably improve efficiency.

As of July of this year, the HKS 4 (EL) will be available with CFRP components that have proved so successful since 2007; this design feature will enable the machine to operate even faster than the previous version. The weight of the bars on the revamped machine has been reduced by up to 25 %, and the entire technical concept of the machine has been adapted accordingly. The working width is 18o", the speed has been increased from 1,400 min⁻¹to 1,8oo min⁻¹, and the rigidity and temperature stability have also been improved.

The threshold values in relation to fluctuations in the ambient temperature in the production hall have been extended from +/- 20°C to +/- 50°C. Loss of efficiency as a result of time-consuming needle tool adjustment and reduced speeds following long down-times are now a thing of the past. The machine is available in working widths Of 130" (136"), 18o" (186") and 210" (23.8").
The gauges remain unchanged.

Customers all over the world are extremely impressed by the advantages of this concept in terms of machine availability and productivity. Textile producers in the USA, Japan, Italy and China are already awaiting the arrival of the new four-bar, high-speed tricot machine that can easily surmount any of the obstacles that have previously stood in the way of increasing performance.
Both textile companies in search of new applications and innovative fabrics, as well as producers of established standard articles will find that the 14KS 4 (EL), with its CFRP components, is the ideal machine for meeting all their needs. In general, the machine has been designed to produce automotive textiles, upholstery and shoe fabrics, and sportswear, outerwear and cleaning textiles.

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