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Innovative solutions
Corporate Highlights
from KARL MAYER
for the textile
KARL MAYER is technology and market leader as well width from 136" to 186" has increased output even
as driving force for innovations in textile machinery more. The output is also higher than weaving mills. At
building. The manufacturer offers perfect solutions for a width of 186" and a speed 800 min−1, the TM 4-TS
warp knitting, technical textiles and warp preparation EL has a daily production rate of about 1,800 kg of
for weaving and under the KM.ON brand digital terry fabrics at a weight of 400 g/m2, 250% more than
solutions for all customer groups. The customers are on an air-jet loom.
active in the most diverse areas and in all parts of the
world. Especially for textile companies in Pakistan Moreover the TM 4 TS-EL consumes roughly 87% less
KARL MAYER offers the warp knitting machine for energy per kilogramme of produced fabric than air-jet
producing terry fabrics from staple-fibre yarn, the TM looms, which require a large amount of energy to
4 TL EL, the sizing machine PROSIZE® and the produce the compressed air. And the production of
indigo dyeing machine PRODYE, which give them warp-knitted terry fabrics requires no sizing process.
advantages in local and international competition. This saves on textile chemicals, effluent and energy to
the value of roughly 0.20 US dollars/kg. This
The TM 4 TS EL, the fastest way to fluffy fabrics corresponds to a share of roughly 30% of the
The TM 4 TS EL can efficiently produce terry fabrics production costs (without the yarn) when producing
with long repeats, hems and borders. This new the raw fabric.
machine is extremely efficient and is proving itself well
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 specialise in producing
textiles having low weights and less dense
constructions. When producing lightweight terry
goods, the high loop stability of warp-knitted fabrics
Karl Mayer The TM 4 TS EL compared to woven fabrics is a particular advantage.
Generally speaking, the loop stability of warp-knitted
on the market. The high speed of the TM 4 TS EL is terry fabrics is quite unique - thanks to the stitch
particularly evident when producing bath towels and tying-in arrangement. Thanks to the EL control
robes with loop-free stripes and long repeats. The system, and particularly to the repeat function, the
modern EL system enables this terry tricot machine to length of the hand towels can be changed very
produce large fabric webs with flat sections and hems quickly to suit customer requirements.
in the lengthwise and crosswise directions at a
production rate that is 30% higher than its Perfect weaving results, thanks to PROSIZER®
predecessor, the KS 4 FBZ. Increasing the working Typical features of the sizing machine PROSIZE® are
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Karl Mayer PROSIZE
its high operator convenience and perfect process size application is perfect, despite the yarn density as
control; the sized warp beams ensure maximum ends/cm is higher than the known limit given by
efficiency in weaving. Combination size boxes with conventional technology. The higher size uptake and
and without prewetting device ensure short yarn associated yarn coverage density means that the
paths. Machine designed as one-box version process can be changed over from double to single turbulent application zones, dead zones are avoided produce less waste and enable deeper, brighter
(floor-type execution) and as double-box version size box processing in the denim, home textiles and and concentrations, temperatures and viscosities are indigo shades to be produced. The dye add-on as a
(overhead execution) can be offered in different clothing sectors, for example; this is beneficial to the equalised. The size film formation is uniform and the percentage of the total yarn weight is 5.5 % maximum.
constructions to meet every requirement. Cylinder sizing result. The onebath system simplifies process warp in the wedge absorb size on the upper and This warp preparation equipment is also highly
driers in various arrangements guarantee a rapid and control and the adjustment of the wetting quality. lower sides. Furthermore an extremely efficient filter productive. The PRODYE-S can double output when
gentle drying of the yarn. The sizing machine. When producing bed linen, for example, high-quality system guarantees the fresh and filtered size processing lightweight denim. The market has been
sized warps can be produced in a working width of application on to the yarn. This performance causes extremely impressed by the performance offered by
The heart of the PROSIZE® are the size boxes HSB 2,800 mm, and there is no risk of the yarns sticking an increasing of power anchor over the width and KARL MAYER ROTAL’s indigo dyeing machines.
and VSB. The size boxes operate with an application together. length of the warp, which is beneficial for the
system for which a patent has been applied and subsequent stages in the value-added chain. Much What makes PRODYE so interesting is that it is based
granted. A new feature is that an immersion bath is no The clever process design allows a saving of the size less fiber fly is generated in sizing and weaving , on well-thought-out components. One of these
longer used. Instead of the usual immersion bath, the material upto 10 % and the possibility to reduce as which increases efficiency considerably. innovative elements is the Double Vario dyebath,
size is applied in three, highly turbulent, homogeneous max as possible the liquor level in the box. That which operates on the basis of a well-thought-out
application zones, with spray bar technology and a permit to decrease effluent loads in sizing and Sophisticated technology for the denim sector cross-flow system for perfect dye liquor circulation to
subsequent application/squeeze roller system. The finishing. Thanks to no immersion system splashing KARL MAYER offers one-stop solutions for slasher give a uniform dyeing result. Additionally, the Quick
so-called sponge effect comes into play here: in the is not present anymore. The ergonomic design of the and rope dyeing with its Centre of Excellence for the Oxidation zone operates with temperature-controlled
first zone, the dry yarn is dipped into the wedge of new size boxes allows an easier access by the denim sector, KARL MAYER ROTAL. Compared to air flow to guarantee uniform dye uptake. Rejects are
liquor between the two rollers, squeezed, and then operator, also in case of wider working width. Vertical conventional machines available on the market, the also reduced and the colour tone of the warp yarn
impregnated again in the second zone. The moist yarn pass also means that the VSB makes even more PRODYE-S and PRODYE-R indigo dyeing machines sheet is more uniform than with conventional
yarn can then absorb the sizing agent more space available for carrying out simple manual from KARL MAYER ROTAL consume less water, techniques.
effectively. Thanks to that a yarn coverage factor of adjustments. The operative also has an unrestricted
100 % is possible, 20 % higher than with the view of the entire process.
conventional immersion process. The uniformity of Thanks to the intensive size circulation in the highly
July/August 2019