Stands A 2. 315 and B 6. 305/400 – listen to the music of the future

The range of machinery being exhibited by the KARL MAYER Group at ITMA 2007

(PresseBox) ( Obertshausen, )
KARL MAYER will once again be presenting its range of machinery at ITMA 2007 as a leader in the technology within this sector. It will be showing innovations from the areas of:
-Machines for producing warp knits and specials (Stand A 2. 315)
-Lace machines (Stand A 2. 315)
-Machines from KARL MAYER Malimo (Stand A 2. 315)
-Warp preparation machines (Stand B 6. 305/400)
-Data management (Stand A 2. 315)

Machines for producing warp knits and specials

With the innovations that the KARL MAYER Group has been making in the field of warp knits and special applications, the company will once again be demonstrating at ITMA 07 that it has a perfect understanding of the market and is setting trends there. It will be showing an RSE 6 EL, an HKS 2-3 E and an HKS 3-M, which have all had their speeds increased considerably, and a TM 3 as a new option in the field of three-bar tricot machines and the first step towards implementing the company’s two-product line strategy for these types of machines.


This machine is based on the tried-and-tested basic concept of the RSE series. It is available with either electronic or mechanical guide bar control, and the machines are virtually identical in terms of their operation. However, the speed that the RSE 6 can achieve is something quite new. With six guide bars, it can operate at a speed of up to 1,400 rpm, which is 75% faster than its predecessor. This high-speed machine is ideal for producing filigree-patterned, shaped, stretch and non-stretch lingerie fabrics, and is perfect for working patterns with ‘tat-too’ effects, patterned stretch and non-stretch embroidery grounds, smooth fabric panels and semi-technical textiles. The RSE 6 EL version with electronic guide bar control will be on show at the trade fair in a gauge of E 24 and a working width of 130".

High-speed tricot machines

In the sector of high-speed tricot machines, the KARL MAYER Group will be illustrating for the first time the two-product line strategy which it intends to implement in the future. This manufacturer can supply a range of models, depending on the customer’s price range and market segments, i.e. it can supply basic machines with fixed widths, gauges and features for markets with development potential and for newcomers to the market, as well as high-tech machines for widely different business areas and for particularly innovative companies. In this demanding sector especially, KARL MAYER has successfully removed the restrictions on using the machine placed by the wide working widths and high gauges. The key to this success was to use carbon-fibre-reinforced composites (CFRC). A new generation of machines equipped with CFRC bars will be presented at ITMA 2007. The entire technical concept of the warp-knitting machine was revamped to enable the machine to fully utilise the performance potential offered by this new material. The result is that the weight of the bars has been reduced by as much as 25% whilst the rigidity has been improved, and this has enabled the speed to be increased considerably. Above all, however, the use of CFRC materials means that the components are now more temperature-resistant than ever under production conditions. The temperature window, which forms part of the climatic specifications, has been extended from +/- 2° to +/- 5ºC. The HKS 2-3 E and HKS 3-M high-speed tricot machines and a TM 3 will be on show at IT-MA.

HKS 2-3 E

By using CFRC materials on the HKS 2-3 E and revising the design of the machine, KARL MAYER has succeeded in increasing its performance by as much as 22% compared with its predecessor. This level of productivity remains constant, even at the high gauges of up to E 40, and guarantees excellent fabric quality. On the new HKS 2-3 E machine, the maximum speed is virtually independent of the gauge, which makes the HKS 2-3 E the ‘efficient professional’, especially in the lucrative area of manufacturing fine, high-fashion lingerie fabrics. The machine on show at the exhibition has a working width of 130" and a gauge of E 36.


The HKS 3-M has been changed over to the concept of using CFRC materials in time for ITMA, and this has led to a considerable increase in its performance. The speed has been increased by up to 35% compared to its predecessor, and this will depend on the gauges and widths. The length of the bars is approx. 5.50 m. The price: performance ratio has been improved even further for virtually the same purchasing price. An HKS 3-M having a working width of 218" and a gauge of E 28 will be on show at the trade fair and will be producing a fabric for use in car headliner.

TM 3

This machine has a completely new design and, with its excellent price: performance ratio, is designed to cater for the market specialising in non-stretch fabrics. The special technical features include a working width of 186" max, a simple KAMCOS® system, i.e. an operating concept with no internal or external networking possibilities, and specific optional features. Gauges E 28 and E 32 are available, together with various batching systems, feeler roller functions and yarn monitoring facilities. A cheaper version having two guide bars and beam positions is also available. The options available for designing the product are therefore restricted by the price, and there is no scope for catering for specific customer requirements, but the machine is ideal for companies which are active on specific markets.

Lace machines

The KARL MAYER Group is injecting even better performance, creativity and economic viability into the lace machine sector in the form of its Textronic® Lace TL 43/1/24, which leaves nothing to be desired in terms of the high-quality relief lace that it can produce. Also available in this sector is the new Rascheltronic® RSJ 5/1 EL, which offers a level of flexibility that has never been reached before.

Textronic® Lace TL 43/1/24

KARL MAYER’s new Textronic® Lace machine features many new improvements in terms of its performance, and its productivity has been increased to maximum levels whilst producing a textile product of consistently high quality. The TL 43/1/24 can reach speeds of up to 600 rpm, which represents an increase of 20% compared to the low-bar Textronic® Lace machine available on the market. The number of pattern bars behind the fall plate has also been increased from two to 14 strings on this new model, which gives even greater scope for creative design. The extra pattern bars have enabled new designs to be developed which, together with a shog distance of up to 170 needles, make it possible for manufacturers of Textronic® lace to produce items of higher quality than similar products available on the market.

RSJ 5/1 EL

The new Rascheltronic®, offers even more impressive patterning possibilities and rapid lapping changeover, together with simple operation and the usual high machine speeds of up to 1,100 rpm. This makes it possible to produce short runs efficiently, and reduces the time needed for developing new, innovative fabrics. With its new EL system and the tried-and-tested piezo jacquard mechanism, the RSJ 5/1 EL enables specific functional zones to be worked into the textile. Ground guide bars GB 5 and GB 6 operate shog paths of up to 170 needles to ensure that these zones are in the right location and have the required size. The ‘Multi-Speed’ sequential yarn feed is another important new feature, and this enables various stitch densities having different elongation values to be worked in the fabric. The machine on show at the trade fair has a working width of 130" (330 cm), a gauge of E 28, and a beam mounting arrangement of 4 x 32" or 3 x 21". It will be producing fabric panels in Munich for making-up into functional underwear.

Machines from KARL MAYER Malimo

One of the areas that KARL MAYER Malimo Textilmaschinenfabrik GmbH will be concentrating on at ITMA is the market for coating and backing substrates. In the last few years, this has proven to be a stable business sector worldwide, offering a considerable growth potential and a wide range of different end-uses.


The high-speed raschel machine (Fig. 4) with parallel weft insertion can knit weft yarns and filler threads in layers of 90º and 0º in a straight configuration, and fix them in place with the knitting yarns of the front guide bars in line with the pattern. This produces a textile having an exceptional tear resistance and tear propagation resistance, with its own unique and versatile appearance. The technical features of the RS MSU S include a working width of up to 6.20 m, a choice of three or two guide bars, N-pattern drive with pattern discs, electronically controlled fabric take-up with two separately driven 3-roller systems, and the latest generation of weft insertion system. This enables the carriage to move separately in the x- and y-directions and increases the speed and acceleration of the insertion carriage. Further advantages of this optimised weft insertion system is that the weft yarns are inserted gently, and the process reliability has been increased. As well as optimising the weft insertion system, recent improvements made to the RS MSU S have concentrated on revising the design of the control logistics. The key elements here in-clude the integration of the peripheral equipment and systems into the central machine computer - for fast and easy handling.

Warp preparation machines

In this sector, KARL MAYER has been following a strategy of providing the right automatic warp preparation machine to suit every warp length that has to be produced, and will be demonstrating this at ITMA by exhibiting two new machines, the GOM 24 and the Nov-o-matic. By selecting the most appropriate models from the range consisting of the GOM 8, GOM 16 and GOM 24 sample warping machines and the Rob-o-matic and Nov-o-matic section warping machines, the customer can create the best configuration of machines to suit his own particular requirements. KARL MAYER will also be showing a beaming machine, various types of creel, a size box and the new Smart Beam data management system at ITMA.

GOM 24

The GOM 24 is designed for the production of sample and production warps in lengths of up to 1,050 m, and thus complements the production repertoire of the other two models in the sample warping machine range. Until now, this has been made up of the GOM 8 for lengths of up to 420 m and the GOM 16 for lengths of up to 700 m. The quality of the beams produced on the GOM 24 has been improved even further and its production rate has been increased by 30% compared to the next machine in the range, and it has been equipped with a number of clever, technical features to achieve this. It operates from a circular creel with 24 instead of 16 packages and with magazine loading. Once the first batch of yarn has been used up, the next magazine, which is the same size, is introduced continuously without stopping. Furthermore, a new, patented leasing function guarantees perfect leasing, regardless of the operating conditions.


This new automatic section warping machine can produce short and production warps in lengths of up to 2,000 m. It has a compact, space-saving design, and a construction that is intended to provide an excellent price:performance ratio. It also offers short setting-up times and a high level of productivity. In order to achieve this, the new warp preparation machine uses KARL MAYER’s tried-and-tested leasing system with its optimised technology. Thanks to the intelligent design of this system, the leasing function, with up to seven sizing divisions, is carried out automatically at a speed that has never been attained before, and this is done without any additional subsequent processing during the beaming process.

Beaming machine

KARL MAYER will be presenting a new model at ITMA from its range of beaming machines for sizing and assembly beaming and for producing warps directly from a creel, and this features a number of innovative solutions. For example, the 4-roller drawing-in unit has been completely redesigned so that drawing-in is now much simpler. The entire control system of the sizing and assembly machines has also been integrated into the beaming machine. This decreases the amount of space needed by the control system, reduces assembly times considerably, and eliminates possible sources of error.

Smart Beam

Smart Beam is the name of a process for which KARL MAYER has filed a patent, for reliably transferring data during the production process. The system involves fitting the warp, knitting and direct beams with RFID transponders carrying all the information needed during the subsequent production processes. The RFID transponders are fitted with a microchip, attached to both sides of the beam flanges and are supplied with information using a read/write unit (Fig. 5) via the machine control system. During further processing of the ‘intelligent beams’ on KARL MAYER Rotal’s sizing machine, all the production data can be read by the read/write unit and are available for controlling the sizing machine The advantage of this type of data flow is that even large volumes of data can be transferred securely and reliably, mistakes in inputting data are ruled out, and the setting-up times can be reduced.

Data management

As far as data management is concerned, the developers at KARL MAYER have been concentrating on the concept of integration through networking and data transfer via open interfaces. New software solutions can now bridge the gaps in the online flow of data and have enabled information systems to be used more widely. Special developments in this area on show at ITMA include the OPC open data interface for KAMCOS® and a fabric scanner, which is integrated into the KAMCOS® network. The use of the KAMCOS® OPC interface can be demonstrated very impressively using the Knitmaster module from Barco.

OPC interface for the KAMCOS® system

Transparency means efficiency! The KARL MAYER Group has been following this strategy for many years now, and as early as 2003, the company introduced the KAMCOS® system and paved the way for reliable, fast and fault-free data transfer via online data flow systems. By the end of 2007, it will also be possible to transfer all the relevant machine parameters into the client’s own specific company network system. The ‘open software interface’ needed to do this is provided by an OPC Server. This Openness, Productivity, Collaboration Server (OPC) can be installed on any KAMCOS® machine with a network interface and permits real-time access to the main machine data. All the KAMCOS® machine parameters required can be integrated into the customer’s PDC software for providing specific, targeted evaluation and control as part of the company’s own quality management system or for optimising manufacturing efficiency.

Barco: a new systems partner with the Knitmaster program

The KARL MAYER Group will be exhibiting at ITMA with the Belgian manufacturer, Barco, another certified systems partner, at its side. This global company specialises in developing products for use in process and operations visualisation in the weaving sector, for example. The Knitmaster program, which can be linked to KARL MAYER’s high-tech machines, can now provide warp knitting companies with a tailor-made solution for efficient machine data collection and networking. The software system uses the OPC interface of the KAMCOS® system for rapid and reliable data transfer, and can also produce clearly arranged statistics and other specific analyses. The specific functions of this system will be on view live on KARL MAYER’s stand at ITMA. Representatives of Barco will be demonstrating the Knitmaster system, and will be available for answering any questions.

The integrated fabric scanner

The fabric scanner can be used for analysing the quality of the fabric surface and has been available for many years. What is new, however, is that it can now be integrated into the data network of the KAMCOS® system via Ethernet access. The advantage of this networking system for the client is that the information on the fabric quality is processed in the form of a graphic image at the Operator Interface. The colour of the different indicator lights, i.e. red, yellow and green, provides the operative with detailed information on a real-time basis at a glance. While the fabric is being produced, the operative on the factory floor can keep an eye on what is going on reliably and easily, and can adjust the machine parameters if necessary. Another advantage of integrating the fabric scanner into the KAMCOS® system is that programming the scanner unit no longer requires special know-how and a separate hand terminal. The system is operated exclusively via the Operator Interface.
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