#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.

STOLL in focus:

At the beginning of this year, KARL MAYER announced that it would be shifting its focus back to its core areas of warp knitting, warp preparation and technical textiles. As part of this strategic realignment, the flat knitting machine business under the STOLL brand will be discontinued. The Reutlingen plant will close down on 31 October 2025. Production in China will end in December 2025. This was an extremely difficult decision for KARL MAYER.

KARL MAYER develops seersucker WARP KNITS with even more character and style

Seersucker fabrics are icons of the clothing industry and assure their manufacturers' success. Just in time for ITMA ASIA + CITME 2025, the textile product developers at KARL MAYER have succeeded in creating brand new variants of this material. These fancy newcomers feature unique bubble effects and, with their new dimensionality, inject extra dynamism into the textile surface – and into the market.

The KARL MAYER Warp Knitting Business Unit at ITMA ASIA + CITME 2025

The manufacturing of warp knitting machines has made KARL MAYER a leader in its field. It remains the company’s most important Business Unit today and has established its name as a brand in the warp knitting industry. KARL MAYER stands for the very highest quality, performance and technical progress. In a persistently difficult market environment, the company is seeking to strengthen its outstanding reputation and, above all, focus more than ever on innovation. The man responsible for this reorientation is Axel Wintermeyer, who has been President of the Warp Knitting Business Unit at KARL MAYER since January 2025 and is also part of the Management board.

Lutz Wolf becomes CEO of the KARL MAYER Group

Effective 1 November 2025, the Supervisory Board of the KARL MAYER Group, a leading global provider of solutions in textile machinery manufacturing, has appointed Lutz Wolf (51) as the new sole CEO of KARL MAYER Holding SE & Co. KG. Wolf will assume overall responsibility for the internationally active group of companies, which has its headquarters in Obertshausen, Germany.

KARL MAYER shows new solutions in its core technology at ITMA ASIA + CITME 2025

“How can I increase my efficiency? How can I boost my productivity? How can I identify new business areas?” No matter what customers have in mind, KARL MAYER takes care of it! “WE WARP. WE KNIT. WE CARE.” This is the motto of the company’s 360 m² booth A 301 in hall 5 of the Singapore EXPO and the standard KARL MAYER sets for its work.

The Address of innovation and investment in textile technologies: ITM 2026

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Heimtextil 2026 strengthens the global home textile industry with trends, designs and AI technologies

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A circular European value chain turns post-consumer textile waste into new garments for Dutch retailer Zeeman

A closed-loop recycling project has successfully transformed 24 tons of post-consumer textiles into nearly 50,000 garments for Dutch retailer Zeeman, with each product containing a high-rate of 70% recycled content. This achievement represents a major milestone in accelerating textile-to-textile recycling in Europe.