With increased performance, quality and flexibility, the machines produced by this traditional manufacturer have enjoyed considerable success. One of the most important chapters in the company's history was the integration of carbon-fiber-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 and are more rigid. The high temperature stability of the CFP materials enables the window for problem-free machine operation to be increased from +/- 2ºC to +/- 5ºC, and even to +/- 7ºC.

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 series was 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.

Developers and engineers have come up with a solution for high temperature stability, which is now a standard feature of this new warp knitting technology. The lynchpin of this efficiency was to substitute the old continuous, tempered shafts for controlling the bars with components that have been divided 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. 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 shorter start-up times, machines with second generation CFP technology are more stable to ambient temperatures, and thus guarantee a high gauge accuracy.
The changeover 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.