#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.

SHIMA SEIKI to exhibit at Première Vision Paris

Leading digital textile solutions provider SHIMA SEIKI MFG., LTD. of Wakayama, Japan will exhibit at Première Vision Paris in Paris, France next month. The company will exhibit in the "Smart Creation" area, dedicated to showcasing cutting-edge technologies that integrate sustainability and innovation. The knitting expert will be demonstrating solutions that optimize product development workflows and enhance sustainability through proposals in Digital Product Creation (DPC).

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.

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.

Global cotton production projected to outpace consumption, but risks remain

Global cotton production is projected to reach 26.2 million tonnes in the 2026/27 season, marginally outpacing estimated consumption of 25.9 million tonnes. However, early-season production risks — including weather volatility and pest pressures — could narrow that buffer as the crop progresses, according to the September 2026 issue of Cotton This Month, published by the International Cotton Advisory Committee (ICAC).

European textile industry calls for €10 handling fee on ultra-fast-fashion imports

The introduction of the €3 customs duty on low-value imports marks an important milestone in Europe’s efforts to address the challenges created by the rapid growth of ultra-fast-fashion imports. Together with the abolition of the €150 customs duty exemption, it demonstrates that policymakers are willing to act when market distortions become impossible to ignore. However, the European textile and clothing industry considers this a first step rather than the final destination.

From smart jackets to laser technology: Mona Neubaur explores Textile Factory 7.0

As part of her summer tour, North Rhine-Westphalia’s Minister for Economic Affairs and Climate Action, Mona Neubaur, visited Textilfabrik 7.0 in Mönchengladbach to experience the project’s innovations first-hand. Under the motto “smart and clean”, the visit focused on innovative technologies and sustainable alternatives for textile production - from smart jackets to the decolourisation of textiles using fungal cultures.

Cinte Techtextil China 2026 has opened today, bringing global innovations and resources to Shanghai

As Asia’s premier platform catering to the evolving needs in technical textiles and nonwovens, Cinte Techtextil China has opened today at the Shanghai New International Expo Centre, gathering over 300 exhibitors from 15 countries and regions. Across Halls W3 to W5, this edition will create chances for fast-growing sectors and emerging trends – such as Mobiltech, Medtech & Protech, Indutech and more. The curated zones, pavilions, and fringe programme are designed to better connect exhibitors with targeted buyers from across China, Asia-Pacific, and further afield. Meanwhile, the Association Village will gather international industry associations to foster even more global collaboration.