#Knitting & Hosiery

2020-02-27

Constant control of yarn tension

Modern sensor technology and data processing systems can be used to control all the important processing parameters and also to implement a wide range of optimisation measures. The production sequences can be optimised, as well as entire value-added chains. The efficient monitoring of yarn tension and feed during warp preparation can increase weaving efficiency by up to 5 %.

The new MULTIGUARD yarn monitor gives advance warning of a yarn breakage

The new MULTIGUARD stop motion from KARL MAYER can make an important contribution here. This innovative system gives a warning in the event of yarn breakages or tension peaks, and generates parameters that can be used for internal production data management as well as external quality assurances within the framework of a quality management system.

All the yarn tension levels at a glance

MULTIGUARD continuously determines the tension values of each individual yarn at the exit of the creel and transmits the data to a computer for comparison with the target values. This generates a clear status report. The coloured indicators show the customer immediately which creel position lies within the tolerance, warning or stop ranges. This enables him to intervene quickly in the warping process if there are any deviations from the target values. The specific, measured tension values are displayed in a compact diagram. They can be used for internal analyses and for quality management of the warping process. KARL MAYER has also developed the PROACTIVE-Warping three-level, modular recording system, whereby each level contains more information. Module 1 manages all the basic data supplied by sensors on the warping machine relating to the warping or beaming quality.

For example, the data relates to the exact positioning of the bands in relation to the drum axis. Level 2 complements these values with optical analyses from an integrated camera on the machine, whereby the focus is on the width, position and parallel arrangement of the bands. In module 3, the data is also transferred to the quality record from the creel monitoring system, i.e. the individual yarn tension values from the MULTIGUARD system.

A good start on the market

MULTIGUARD was launched as a prototype for the first time at ITMA 2019, and this innovative system generated a huge level of interest. “The possibility of detecting critical deviations in yarn tension levels early on, and to intervene in order to adjust them was well received by our customers,” says Martin Fuhr, the Head of Development in KARL MAYER’s Warp Preparation Business Unit. A Belgian customer has already ordered the new yarn monitoring system. Further promising projects are currently being negotiated. MULTIGUARD is suitable for every type of creel. It is integrated into the machine’s software and monitor on new machines.

More patterns, less effort: the MULTI-MATIC® at Rohleder

Rohleder is one of Europe’s most modern weaving mills. For over 80 years, the family-owned company has been developing and manufacturing premium fabrics for brands, retailers and private customers – 100% Made in Germany. This success is made possible by a consistent focus on design, quality, and functionality, as well as by continuous investment in state-of-the-art production facilities. Rohleder also relies on innovative technologies in warp preparation and has been collaborating with KARL MAYER for many years. As recently as 2023, a MULTI-MATIC® was delivered to the company’s headquarters in Konradsreuth.

The new RJ 4/2 EL revolutionizes body mapping and expands creative possibilities – from smart lingerie to sporty athleisure designs

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.

The new RDJ 7/3 defines the design footprint of modern athletic shoes

Stylish, functional, and efficient to produce – spacer fabrics are the all-arounders among textile materials. These versatile fabrics are particularly in demand in the sports and casual footwear sector, as they combine comfort, breathability, and design freedom. At the same time, this industry is trend-driven, dynamic, and price-sensitive like few others. Innovations are therefore a decisive factor for success. With the RDJ 7/3, KARL MAYER offers a solution specifically tailored to these requirements. The particular strength of the new double raschel machine: its exceptional flexibility, thanks to its three jacquard bars.

SHIMA SEIKI brings new flat knitting technologies to FEBRATEX 2026

Leading flat knitting solutions provider SHIMA SEIKI MFG., LTD. of Wakayama, Japan, together with its Brazilian representative BRASTEMA TECNOLOGIA TEXTIL LTDA., will exhibit at the Brazilian Textile Industry Fair (FEBRATEX 2026) this month. On display will be a roundup of SHIMA SEIKI computerized flat knitting technology, represented by WHOLEGARMENT® knitting machines, computerized flat knitting machines featuring a brand-new model with high productivity and excellent cost performance, a glove knitting machine and the latest digital solutions.

BASF opens global diaper and superabsorbents performance lab in Mumbai

BASF has officially inaugurated its new Performance Lab for diapers and superabsorbents (SAP) in Mumbai on August 18, 2026, which will provide technical and application services to superabsorbent customers globally. The new lab of BASF’s Hygiene Solutions business has been established in less than a year and is part of BASF’s Innovation Campus Asia Pacific in Mumbai, BASF’s second largest R&D site in Asia Pacific established in 2017 under BASF Chemicals India Private Limited.

Naia™ from Eastman strengthens western hemisphere textile connections at Apparel Sourcing Show Guatemala

As brands and retailers explore more diversified and responsive sourcing networks, the Naia™ brand from Eastman is strengthening its engagement with the textile and apparel value chain across the western hemisphere. From August 18–20, the company will participate for the first time in Apparel Sourcing Show Guatemala, a regional meeting point for apparel sourcing, manufacturing and nearshoring.

Dornbirn GFC 2026 expands conference program with new thematic sessions

For 65 years, Dornbirn GFC has stood for innovation and is one of the world’s leading conferences in the fiber industry. From September 16 to 18, 2026, the international fiber community will meet in Dornbirn, Austria, to discuss current trends, technological developments, and forward-looking solutions. More than 600 experts from industry and academia from over 30 countries are expected to attend. With around 100 presentations by renowned speakers, a 2,5-day conference program, and three parallel presentation rooms with moderated sessions, Dornbirn GFC provides a first-class platform for knowledge exchange, networking, and international collaboration. Together, participants will generate ideas and impulses that will sustainably shape the future of the global fiber industry.

Europe is committed to recycling end-of-life wind turbine blades

Starting in 2026, Europe’s wind energy industry has committed itself to ensuring that wind turbine blades do not end up in landfills once they reach the end of their service life. The EU-funded research project REWIND is exploring ways to reuse this composite waste. The German Institutes of Textile and Fiber Research Denkendorf (DITF) are one of 13 project partners from seven countries.