#Weaving

2024-11-28

Innovations for warp preparation at the cutting edge

At ITMA ASIA + CITME in October, KARL MAYER presented solutions for lower production costs and environmental impact and greater efficiency in the warp preparation sector. After the trade fair, the company can draw a positive conclusion, both in terms of the number of visitors and the quality of the discussions.

The KARL MAYER Warp Preparation Business Unit draws a positive conclusion after ITMA ASIA + CITME 2024 © 2024 KARL MAYER

In addition, the overall presentation was right on target. As at every ITMA, the KARL MAYER stand was a meeting point for the industry. “In a market that is increasingly characterised by Chinese competitors and price pressure, we have demonstrated our strong presence,” says Dieter Gager. The Vice President Sales & Marketing at KARL MAYER’s Warp Preparation Business Unit and his team negotiated numerous projects and discussed upcoming investments in the course of the trade fair. Many manufacturers want to expand or modernise and are gathering information, but are waiting for a recovery in global demand, according to Dieter Gager's assessment. When the market picks up, they will benefit from their knowledge of the innovations presented at the trade fair.

One of the highlights was the WARPDIRECT, a latest-generation warping machine with an excellent price-performance ratio. The possible warping speed is an unbeatable 1,200 m/min. The quality of the beams produced is also unrivalled. Thanks to the high level of quality, yarn waste can be saved during the sizing process and the efficiency of the downstream weaving process can be maximised. Other advantages include high operational reliability and less maintenance work. With this performance, the WARPDIRECT attracted the attention of trade fair visitors from Pakistan, Bangladesh and other countries neighbouring China.

Visitors were also interested in two innovative solutions for sizing with advantages when using the PROSIZE®.

The brand new CASCADE system reduces steam consumption by up to 7% thanks to intelligent steam recycling within the machine. This enables significant savings in energy costs and CO2 equivalents over the entire utilisation cycle of the machine and not as a one-off effect.

The second innovation in the group of novelties relating to sizing is the Smart Size Box. This sophisticated technology uses sensors and digital solutions to monitor the condition of wear components, making a valuable contribution to predictive maintenance. The customer can plan interruptions due to maintenance work in advance, avoid uncalculated downtimes and fully utilise the performance potential of the PROSIZE®.

The highly efficient sizing machine operates at a speed of 160 m/min, with 200 m/min possible as an option. With a yarn cover factor of up to 100 % - 20 % more than conventional systems - a high sizing quality is achieved and the range of applications is extended.

The feedback at the trade fair on the Size Box with the big plus in customer benefits was encouraging. “By focusing our development activities on maximum machine availability and digital solutions, we have hit the nerve of the times,” says Dieter Gager.

To ensure high machine availability, a combined Care X-Tend and Connectivity package was also presented at the trade fair. Among other things, the package provides easy access to fast remote assistance. Unlike conventional teleservice support, images and large amounts of data can now be exchanged easily and securely, minimising interruptions to operations.

More Jacquard. More functionality. More fashion.

With the addition of another member to its successful RASCHELTRONIC® family, KARL MAYER is opening up new possibilities for creative product development for warp knitting mills and brands. The RJ 4/2 EL offers with two stitch-forming Jacquard bars entirely new design options for functional sportswear and bi-elastic lingerie. Available in gauges E 28 and E 32, this new model helps manufacturers set their collections apart from the competition. The fine E-32 gauges, in particular, impress with their clean surface, a pleasantly soft feel, and an exceptionally elegant look.

KARL MAYER's HKS 2-SE Expands Possibilities for Premium Stretch WARP KNITS

Warp knitted fabrics with a woven look are more in demand than ever in the fashion and apparel industries. Stretch WARP KNITS, in particular, impress with their freedom of movement, breathability, and virtually wrinkle-free wear – thereby opening up new style worlds such as smart casual or business casual. When it comes to the highly efficient production of premium-quality stretch WARP KNITS, the HKS 2-SE has long been the machine of choice. KARL MAYER’s best-selling tricot machine produces standard elastic fabrics characterized by high gauges, smooth, delicate surfaces, and a soft hand feel.

Footwear innovation enabled by warp knitting technology– insights from New Balance

The future of the athletic shoe is increasingly being shaped on warp knitting machines. For KARL MAYER, the footwear industry is one of the most important growth markets – and one of the sectors where innovative textiles can realize their full potential. In his keynote address at the opening of KARL MAYER’s TEXTILE INNOVATION CENTER in Obertshausen in April, Vishnu Prakash Muthusamy, Senior Textile and Materials Engineer at New Balance, explained the opportunities that warp knitting technology opens up for performance, sustainability, and faster development processes, and why textile manufacturers are transitioning from suppliers to development partners.

Fewer pores, greater impact tolerance: Peter Dornier Foundation Prize 2026 honours material research on fibre-reinforced composite components for aerospace industry

Microscopically small pores that form during manufacture, or barely visible impact damage, can severely impair the load-bearing capacity and service life of fibre-reinforced composite components. Two young researchers have presented groundbreaking work in this field and will both be awarded the 2026 Peter Dornier Foundation Prize: Dr.-Ing. Benedikt Neitzel from the Technical University of Ilmenau for his doctoral thesis on pore minimisation in the RTM process, and Johanna Buschmann, M.Sc., for her master’s thesis, completed at the German Aerospace Centre, on the improved impact tolerance of 3D fabrics compared to 2D laminates.

Itema reaffirms its commitment to the Syrian textile industry at NasTex 2026

From July 18th to 21st, Itema will exhibit at NasTex at the Damascus Fairground (Hall 11 – Stand C02), marking its return to one of the Middle East’s historically significant textile markets. Itema will showcase advanced weaving technology designed to support the competitiveness and technological evolution of Syrian manufacturers and announces a new partnership with Growfast Agency as the sole agent of Itema in Syria.

Rieter sees Barmag integration on track as orders and sales rise

The first half of 2026 was shaped by the successful completion of the largest acquisition in Rieter’s history. The Man-Made Fiber Division enables entry into the growth segment of man-made fibers and sustainably strengthens Rieter’s market position in the Asia region. The expanded Group is now the world’s leading system supplier for the processing of natural and man-made fibers. In the first half of the year, initial cost savings in material costs and operating expenses have already been realized. The targeted synergies are expected to amount to at least CHF 20 million by the end of the 2028 financial year. Due to the completion of the acquisition on February 2, 2026, the first half of the year for the Man-Made Fiber Division only amounts to five months.

C&S strengthens its governance to support its evolution

C&S announces the appointment of Marco Lucietti to its Board of Directors. With extensive international experience across the textile and denim industries, Lucietti will work alongside CEO Federico Corneli, contributing to the company’s managerial development, organizational structure and long-term strategic direction.