Highlights on the exhibition stand W3 B01 are different types of yarn tensioners, a V-creel, the sizing unit of the SUCKER SIZE and the direct warping machine WARP-DIRECT. Moreover, a newly designed Wefttronic^® machine will also be displayed.

Visitors to the stand W1 F21 will have the opportunity to see KARL MAYER’s latest innovations in the sector of warp knitting machines: the extension of the RD product range and a new four-bar terry machine, TM 4-T.

Innovations in the RD product range and in tricot machines

The newcomer in the RD product range is the RD 7/2-12 N or EL which is available in gauges of E 18, 22 and 24 and operates at a working width of 138". It is based on the same principles as the RD 6 1/1-12 but has one guide bar more than its six-bar sister machine, so that it can produce a wider range of patterns. A new level of flexibility has been achieved by incorporating the EL guide bar movement control, which is available as an optional configuration and with Multispeed system. It is possible to produce many new variations by superimposing constructions having different colors and densities in the cover faces of the 3D products to produce three-dimensional optical effects. The lengthwise repeat is virtually unlimited. The possibility of adjusting the distance between the knock-over comb bars between 2 and 12 mm also offers an additional advantage in the version equipped with electronic guide bar control.

Manufacturers of shoe textiles are particularly interested in the extended patterning possibilities of the RD 7/2-12 - and in its high level of efficiency. This innovative machine will be producing patterned fabrics for footwear at ShanghaiTex.

KARL MAYER has also extended its range of four-bar tricot machines for the polyester terry goods market with the addition of a further model named TM 4-T. The visitors can look forward to a completely new machine with an exceptional price-performance ratio.

The new Wefttronic^® RS 2

Wefttronic^® is a new machine platform, with which KARL MAYER has revised and improved its weft-insertion machines in terms of their width and square meter production rate. The first machine featuring this completely revamped machine concept is the Wefttronic^® RS 2.

The new Wefttronic^® RS 2

Compared to its predecessor, it has been equipped with a range of new technical innovations. One of the latest innovations on the Wefttronic^® is that the weft insertion system has been completely revised. The central machine unit has been fitted with an optimized weft chain on both sides, and its operating functions have been improved using sophisticated technology. Moreover, the machine has a wider working width of 268", and a considerable increase in the square meter production rate has been achieved for the same speeds. The machine handling has also been improved. The design of the new Wefttronic^® allows easy access to all the main components, and the modular design facilitates machine assembly, thus, saving setting-up costs and shortening the downtime periods.

Based on this successful concept, KARL MAYER can offer machines in a total of four working widths. Whereas the first model was the widest machine, the version having the shortest width of 138” will be on show in Shanghai. The Wefttronic^® RS 2, E 18, to be shown here in June has a technical configuration which makes it ideal for producing coating/backing substrates, and it can also process high-strength polyester for use in areas having stringent requirements, for example. For some time now, tarpaulins and printed advertising media have been a clear growth area in China.

The V-creel

KARL MAYER’s V-creel guarantees a constant yarn tension over the entire length and width of the warp. The equipment for feeding in the yarns operates without any guide elements or deflection points, reduces the air resistance as a result of the shorter creel length, and guarantees a low yarn tension. These are the most important factors in achieving production speeds of up to 1,200 m/min. The maximum possible speed and efficient handling of yarn breakages and batch changes, without having to thread the yarn into the yarn guide elements, result in an exceptionally high rate of productivity.

The V-creel

The quality of the warp is also excellent. The yarn is taken-off gently thanks to the low yarn tension and the free yarn path, and this minimizes the yarn breakage frequency - and has a positive influence on the subsequent sizing and weaving processes.

The technical and processing parameters that contribute to this performance profile include: an automatic pretensioner that prevents snarling, an efficient balloon limiting system, a cutting device for cutting the yarns in a single sequence when changing the batch, a universal stop tensioner with optoelectronic yarn monitoring.

When the batch has to be changed, the yarns are drawn-in again rather than being knotted, so that there is no restriction in relation to the range of yarns that can be used – even when changing over from single yarns to plied yarns or from very coarse to extremely fine ones. Nor does a different number of yarns between one batch and another create any problems, because the OPTOSTOP yarn tensioners are activated automatically.

The sizing unit of KARL MAYER’s sizing machine, the ‘SUCKER-SIZE’

With the SUCKER-SIZE KARL MAYER is consolidating its market-oriented, staple-fiber sizing concept, and is thus continuing to focus its product range on extremely flexible production concepts.

Warp beams having shorter running lengths for sampling or production can be sized just as economically as longer warp lengths on this innovative machine. The amount of waste has been minimized, the product quality has been optimized and a high operating reliability is guaranteed - a performance profile in which the sizing unit plays an important role.

The size is applied to the warp yarn in the application system by using the proven ‘double dip, double nip’ process. This double dipping, double nipping process improves the adhesion of the sizing agent to the surface of the yarn when compared with other, simple, conventional application systems. The hairiness of the yarns is also reduced.

The design of the sizing unit is based on the technology originally developed by Sucker, but some areas of the machine have been equipped with optimized components. The nip zone, for example, has been upgraded. This zone for reducing the moisture content features two successive nip roller pairs with integrated dipping rollers – a sophisticated design which has now been improved even more, and the two processes have also been harmonized with each other.

With all its optimized features, the revamped sizing unit offers a constant processing temperature as a function of the process and parallel yarn running. The yarn is guided along short paths with a minimum of deflection points, so that it is treated extremely gently. Besides, the handling was also simplified.

The WARP-DIRECT direct warping machine

The WARP-DIRECT machine was taken over from Benninger’s product range. It was integrated into the product line produced by KARL MAYER (China) and the machine concept was adapted to suit the KARL MAYER Group’s strategy.

The WARP-DIRECT

The technical configuration of the WARP-DIRECT guarantees a perfectly cylindrical beam build-up and uniform surfaces – quality advantages that are provided by the absolutely uniform yarn tension and contact pressure.

The contact pressure is produced by a roller which operates according to the principles of force being introduced indirectly. Another technical feature relating to the winding quality is that back beams having a toothed internal taper of 40° are fitted as standard. The interlocking connection guarantees accurate centring as well as non-slip drive and braking of the beam.

If the machine comes to a stop, a whole series of special devices are responsible for guaranteeing efficient management of braking and the downtime itself. These include: hydraulically operated disc brakes at both sides of the beam chuck, an automatic uncrossing device, a kick-back mechanism is responsible for swinging the press roller away hydraulically, a graduated comb which guarantees uniform yarn laying.

The yarns are also guided absolutely accurately and with only minimal free lengths so that they do not become crossed. The width of the yarn sheet is adjusted precisely to the beam, thus, preventing any faults in the area around the flanges. The length of the yarns is also measured accurately. The back beams in the same batch must be wound so that their length is exactly the same so as to minimize waste during sizing, since the batch must be finished as soon as the first beam is empty during sizing.

Sophisticated features for optimizing the handling procedures complement the WARP-DIRECT’s package of advantages.