KARL MAYER is technology and market leader as well as driving force for innovations in textile machinery building. The manufacturer offers perfect solutions for warp knitting, technical textiles and warp preparation for weaving and under the KM.
ON brand digital solutions for all customer groups. The customers are active in the most diverse areas and in all parts of the world.
Especially for textile companies in Pakistan KARL MAYER offers the warp knitting machine for producing terry fabrics from staple-fibre yarn, the TM 4 TL EL, the sizing machine PROSIZE® and the indigo dyeing machine PRODYE, which give them advantages in local and international competition.
The TM 4 TS EL, the fastest way to fluffy fabrics
The TM 4 TS EL can efficiently produce terry fabrics with long repeats, hems and borders. This new machine is extremely efficient and is proving itself well on the market. The high speed of the TM 4 TS EL is particularly evident when producing bath towels and robes with loop-free stripes and long repeats. The modern EL system enables this terry tricot machine to produce large fabric webs with flat sections and hems in the lengthwise and crosswise directions at a production rate that is 30% higher than its predecessor, the KS 4 FBZ. Increasing the working width from 136″ to 186″ has increased output even more. The output is also higher than weaving mills. At a width of 186″ and a speed 800 min−1, the TM 4-TS EL has a daily production rate of about 1,800 kg of terry fabrics at a weight of 400 g/m2, 250% more than on an air-jet loom.
Moreover the TM 4 TS-EL consumes roughly 87% less energy per kilogramme of produced fabric than air-jet looms, which require a large amount of energy to produce the compressed air. And the production of warp-knitted terry fabrics requires no sizing process. This saves on textile chemicals, effluent and energy to the value of roughly 0.20 US dollars/kg. This corresponds to a share of roughly 30% of the production costs (without the yarn) when producing the raw fabric.
The TM 4 TS EL can suit every company strategy for producing terry goods on the basis of tried-and-tested principles. In this case, there are two general approaches. On the one hand, there is the production of heavy fabrics for the high-end segment, where high demands are placed on durability. This innovative four-bar terry tricot machine can produce fabrics having weights of up to 600 g/m². On the other hand, some manufacturers specialize in producing textiles having low weights and less dense constructions. When producing lightweight terry goods, the high loop stability of warp-knitted fabrics compared to woven fabrics is a particular advantage. Generally speaking, the loop stability of warp-knitted terry fabrics is quite unique – thanks to the stitch tying-in arrangement. Thanks to the EL control system, and particularly to the repeat function, the length of the hand towels can be changed very quickly to suit customer requirements.
Perfect weaving results, thanks to PROSIZER®
Typical features of the sizing machine PROSIZE® are its high operator convenience and perfect process control; the sized warp beams ensure maximum efficiency in weaving. Combination size boxes with and without prewetting device ensure short yarn paths. Machine designed as one-box version (floor-type execution) and as double-box version (overhead execution) can be offered in different constructions to meet every requirement. Cylinder driers in various arrangements guarantee a rapid and gentle drying of the yarn. The sizing machine.
The heart of the PROSIZE® are the size boxes HSB and VSB. The size boxes operate with an application system for which a patent has been applied and granted. A new feature is that an immersion bath is no longer used. Instead of the usual immersion bath, the size is applied in three, highly turbulent, homogeneous application zones, with spray bar technology and a subsequent application/squeeze roller system. The so-called sponge effect comes into play here: in the first zone, the dry yarn is dipped into the wedge of liquor between the two rollers, squeezed, and then impregnated again in the second zone. The moist yarn can then absorb the sizing agent more effectively. Thanks to that a yarn coverage factor of 100 % is possible, 20 % higher than with the conventional immersion process. The uniformity of size application is perfect, despite the yarn density as ends/cm is higher than the known limit given by conventional technology.
The higher size uptake and associated yarn coverage density means that the process can be changed over from double to single size box processing in the denim, home textiles and clothing sectors, for example; this is beneficial to the sizing result. The onebath system simplifies process control and the adjustment of the wetting quality. When producing bed linen, for example, high-quality sized warps can be produced in a working width of 2,800 mm, and there is no risk of the yarns sticking together.
The clever process design allows a saving of the size material upto 10 % and the possibility to reduce as max as possible the liquor level in the box. That permit to decrease effluent loads in sizing and finishing. Thanks to no immersion system splashing is not present anymore. The ergonomic design of the new size boxes allows an easier access by the operator, also in case of wider working width. Vertical yarn pass also means that the VSB makes even more space available for carrying out simple manual adjustments. The operative also has an unrestricted view of the entire process.
Thanks to the intensive size circulation in the highly turbulent application zones, dead zones are avoided and concentrations, temperatures and viscosities are equalised. The size film formation is uniform and the warp in the wedge absorb size on the upper and lower sides. Furthermore an extremely efficient filter system guarantees the fresh and filtered size application on to the yarn. This performance causes an increasing of power anchor over the width and length of the warp, which is beneficial for the subsequent stages in the value-added chain. Much less fiber fly is generated in sizing and weaving , which increases efficiency considerably.
Sophisticated technology for the denim sector
KARL MAYER offers one-stop solutions for slasher and rope dyeing with its Centre of Excellence for the denim sector, KARL MAYER ROTAL. Compared to conventional machines available on the market, the PRODYE-S and PRODYE-R indigo dyeing machines from KARL MAYER ROTAL consume less water, produce less waste and enable deeper, brighter indigo shades to be produced.
The dye add-on as a percentage of the total yarn weight is 5.5 % maximum. This warp preparation equipment is also highly productive. The PRODYE-S can double output when processing lightweight denim. The market has been extremely impressed by the performance offered by KARL MAYER ROTAL’s indigo dyeing machines.
What makes PRODYE so interesting is that it is based on well-thought-out components. One of these innovative elements is the Double Vario dyebath, which operates on the basis of a well-thought-out cross-flow system for perfect dye liquor circulation to give a uniform dyeing result. Additionally, the Quick Oxidation zone operates with temperature-controlled air flow to guarantee uniform dye uptake.
Rejects are also reduced and the colour tone of the warp yarn sheet is more uniform than with conventional techniques.
