Second Stage Of Karl Mayer Optimization Program Improves Machine Availability

Obertshausen – March 18, 2010 — Technical progress in the warp knitting sector bears all the
hallmarks of KARL MAYER. With their increased performance, quality and flexibility, the machines
produced by this traditional manufacturer have enjoyed considerable success for many decades all
over the world. One of the most important chapters in the company’s history was the integration of
carbon-fibre-reinforced plastic (CFP) bars into the machines and modifying the design of the
machines accordingly. These high-precision composite components are up to 25% lighter than the
conventional version. They are also more rigid, thus enabling speeds to be increased considerably,
for a simultaneous optimisation of the machine availability. The high temperature stability of the
CFP materials has enabled the window for problem-free machine operation to be increased from +/-
2ºC to +/- 5ºC, and subsequently even to +/- 7ºC.

The company’s tricot machines were the first to profit from this lightweight construction
technology, and have been available with CFP bars since the ITMA fair in Munich in 2007. Once the
gradual changeover of this machine series had been completed, work began on adapting the raschel
machines. The first machine with CFP components, the RSE 4-1, will appear on the market at the
beginning of April 2010. With its revamped bar and shaft concept, KARL MAYER has optimised the use
of this technology and made it easier to operate.

The developers and engineers have recently come up with a solution which has made the high
temperature stability, which is now a standard feature of this new warp knitting technology, to be
achieved more easily and efficiently. The lynchpin of this increased efficiency was to substitute
the old continuous, tempered shafts for controlling the bars with components that have been divided
up into high-precision segments. The shaft is divided into segments according to specific machine
parameters, and it is no longer necessary to carry out the heating-up stage that was previously
required following a machine stoppage. This has reduced the time-consuming heating-up phase, cut
down on energy costs, and dispensed with the need to specifically adjust components during the
start-up phase.

In addition to the short starting-up times, machines equipped with second generation CFP
technology are more stable to ambient temperatures when operating, and thus guarantee a high gauge
accuracy. Even when producing fine fabrics and at large working widths, the production machine runs
smoothly at top speed to produce top-quality textiles.

The changeover of the high-speed knitting machines to second generation CFP components will
start again soon, and will be carried out gradually over the course of the year.

A patent has been applied for to protect this innovative system.

Press Release Courtesy of Karl Mayer

Posted on March 23, 2010