OBERTSHAUSEN, Germany— February 7, 2022 — Lace is a delicate seducer. The more finely crafted its ground structure, the more effective its refined designs come across, and as such, the higher the overall quality. The innovative Symm-Net pieces, which can be produced on Karl Mayer’s new MJ 92/1 B, have a look that sets new standards.

Lace offering maximum clarity and balance

Symm-Net lace is charactezised by an extremely delicate design, offering absolute symmetry. This is thanks to the particular configuration of the MJ 92/1 B — the new multi-bar jacquard raschel machine features a split-design jacquard bar with separate threading, and can thus work using both equal and counter lapping. In addition, the newcomer has two ground guide bars at the back for counterlapped elastane. For Symm-Net’s ground structure, GB1 works a pillar notation whilst the jacquard bar works a counter-lapped inlay. The result is a net structure with absolutely symmetrical, clearly defined symmetry. To perfect the geometry, the two elastane bars with split threading – i.e. 1 in, 1 out – and counter-lapping patterning mirror the movement of the jacquard bar. The lapping patterns thus look as follows: • JB 91: 0 – 0 / 2 – 2 // and JB 92: 2 – 2 / 0 – 0 // • GB 93: 0 – 0 / 1 – 1 // and GB 94: 1 – 1 / 0 – 0 // The ground structure is not only more uniform, but also more stable than its counterparts manufactured with equal lapping. The advantages of Symm-Net are particularly visible when working finer mesh constructions. “When it comes to a delicate appearance, Leavers lace traditionally sets the standard; in particular, Endsor- Net is known for its delicate design. There is hardly any discernible difference with Symm-Net, which should open up new design perspectives, especially for the premium brands in Europe,” explained Jamie Heather, lace expert at Karl Mayer. Symm-Net offers a further advantage thanks to its simple pattern development. For example, the patterning process does not require any updates to the commonly used patterning software, SAPO and ProCad – only the machine database needs to be adapted.

High design flexibility

In addition to the Symm-Net variants, all existing patterns of the OJ 91/1 B, MJ 85/1 B and OJ 83/1 B can be implemented on the MJ 92/1 B in E 24 without restrictions; switching from the new counter lapping to the traditional JACQUARDTRONIC® LACE pattern is seamless. Jamie Heather is certain this flexibility will give customers a real competitive advantage.

All the prerequisites for a bestseller

The MJ 92/1 B has been successfully offered on the market since May 2021. The newcomer is available in gauge E 24, with a working width of 134″. Despite its high design flexibility, it still offers first-class productivity. It can also reach speeds of up to 800 rpm when producing Symm-Net articles. To allow for diverse product design, 88 pattern guide bars and two elastane bars, arranged in 16 shogging lines, are available. Thanks to these features, the MJ 92/1 B mainly produces elastic galloon lace, but also all-over lace for stylish lingerie items. “With Symm-Net articles, our newcomer demonstrates what it can do. The lace with its delicate, symmetrical ground structure makes the MJ 92/1 B particularly interesting for our customers in the western market,” says a confident Sascha Müller, Regional Lace & Raschel Product Owner at KARL MAYER. In addition to efficiently implementing creative lace designs, the new multi-bar jacquard raschel machine offers short changeover times, low maintenance, and easy yet reliable operation.

Posted: February 7, 2022

Source: KARL MAYER Gruppe

OBERTSHAUSEN, Germany — February 3, 2022 — Several Corona waves, supply chain bottlenecks and unforeseen problems such as sudden power rationing in China have caused difficulties in the global textile market in recent years. The highly competitive shoe fabric fabric market has been particularly affected by the difficulties.

Here, only those are successful who react quickly and flexibly meet customer requirements, combine quality with efficiency, hold their own in globalized markets and drive innovation. The Hua Yu Zheng Ying Group (Hua Yu) shows how this can be done. The RD 7/2-6 EN double needle bar raschel machine from KARL MAYER demonstrates what is needed to achieve this.

Hua Yu is a leading warp knitting company based in Jinjiang City, and is one of the first users of the high-performance RD machine. The RD 7/2-6 was launched in 2019 specifically to be more competitive in the shoe fabric market. Just two years later, the newcomer has established itself as the machine of choice among manufacturers worldwide.

Strengthening competitiveness with quality and efficiency

Hua Yu was founded in 1989 and produces warp knitted and knitted fabrics in a vertically integrated process chain with man-made fiber, yarn and textile production as well as finishing and dyeing. More than 400 modern warp knitting machines, including 170 double needle bar raschel machines from Karl Mayer, are running in the warp knitting mill. The output is more than 20,000 t of functional textiles per year. This makes Hua Yu one of the leading companies in the warp knitting sector in China, and one of the largest producers of spacer fabrics in the country. The spacer textiles go mainly to the shoe market. This has been significantly overheated in recent years with full order books and short delivery times. Well thought-out strategies were needed for success. Hua Yu has made its entire manufacturing chain more competitive and strengthened its core competitive advantages in terms of cost and size to respond quickly to external changes. It has also strengthened its technical base. “Besides, the key to our success also lies in heavy investment in Karl Mayer’s advanced machines of high speed and high yield to ensure quality and efficiency,” explained Su Chengyu, general manager of Hua Yu Zheng Ying Group. The RD 7/2-6 EN in particular perfects the balance between these two production factors, Hua Yu is confident. The quality of RD 7 goods is a real competitive advantage. “Of course, fabric produced with Karl Mayer’s machines feels smoother and more homogeneous and has clearer patterns, which are generally acknowledged in the industry,” said Yang Xiaoqing, Manufacturing director of Warp Knitting Division of Hua Yu Zheng Ying Group.

Save manpower with more efficiency and flexibility

Hua Yu operates the RD 7/2-6 EN at up to 1,1000 rounds per minute and, thus, achieves significantly more output than before. The company’s capacities have increased by around 30 percent, according to Yang Xiaoqing. Hua Yu also benefits from the flexibility of the RD model. In the past, the production of warp knitted fabrics with different patterns required machines with different specifications and corresponding operating personnel. This cost material and human resources. Equipped with seven guide bars and EN pattern drives for their electronic control, patterns of the most varied design can be produced on just one machine, thus, meeting the requirements of different applications. In addition, the patterns can be easily changed. “With the RD7 from Karl Mayer, our production efficiency has been increased dramatically. Previously we had one operator on two machines, and now one operator can manage four to five machines. In addition, the company’s capacity has been increased by about 30 percent,” Yang Xiaoqing said.

In addition, the availability of the production equipment was significantly stabilized or improved. The machine failure rate fell from 6 to 3 percent, while operating efficiency increased from 80 to 90 percent.

With fast support to efficient operations

In addition to innovative machines, Karl Mayer offers to Hua Yu sophisticated after-sales solutions for an efficient internal operational procedure.

The innovative knitwear manufacturer is one of the first users of the RD 7/2-6 EN. If questions or problems arise, engineers are immediately on hand to monitor the required data and report back the monitoring results. If necessary, cooperation partners are also involved in problem finding on site. “Karl Mayer has service centers in China’s key warp knitting industrial clusters. It communicates with us in a timely manner, and responds quickly if there were any problems,” explained Yang Xiaoqing.

Hua Yu also cooperates with Karl Mayer’s Academy. The company’s in-house educational facility provides regular training on warp knitting technology and customized training at customers’ premises according to their specific technical requirements. Hua Yu wants to improve the technical skills of its staff and has already had them trained in a course. The first on-site training took place from 5 to 7 January and was very successful.

Co-innovation promotes the differentiation advantage

Technological innovation capability is Hua Yu’s core advantage in a competitive environment that is all about differentiation. The company attaches great importance to technological research and development capabilities. With an R&D team of around 200 employees and more than 36 patented technologies, the company has won a variety of international sports brands such as SKECHERS, ASICS, PUMA, ANTA and LI-NING as long-term partners.

Hua Yu’s definition of innovation is broad. It covers product innovations to meet the needs of the market as well as material innovation in line with the strategy of sustainable development. Innovations in the field of production equipment mainly concern the development and exploitation of machine functions and the exploration of completely new possibilities for fabric production together with the machine manufacturers. Among these, Karl Mayer is an important driving force.

Continue to grow with the right partner

With its well-thought-out strategy, Hua Yu is still on the road to success. In order to expand and develop again, the company had just increased its investment by RMB 3.5 billion in 2019 for a new warp knitted fabric production project. The project will see the construction of a new factory covering an area of 170,000 m². As a partner of Hua Yu, Karl Mayer will also help the company improve its competitiveness in all areas with the new factory and lead it to greater success.

Posted: February 4, 2022

Source: KARL MAYER Gruppe