OBERTSHAUSEN, Germany — June 6, 2021 — KARL MAYER’s WEFT.FASHION TM 3 benefits from the high productivity of the warp knitting mill to produce curtain articles featuring the most popular weaving-like looks. The design potential offered in this process is manifold. Karl Mayer’s textile developers had already started testing out the possibilities on the prototype. Initial work concentrated on the basic structure, while further trials looked at incorporating simple effect yarns as full inserted wefts. The created samples — wafer-thin, extremely transparent and feather-light qualities with a basic organza structure and decorative thread covering the entire surface — were shown at Heimtextil in Frankfurt am Main in 2019 and met with great interest.

In their latest project, Karl Mayer’s textile developers looked further into using effect yarns. They tested the processing of a total of 40 variants of different designs on a series machine that is now available. Among other things, knots, burls, loops, graver hair, fringes, Lurex® spots, mini sequins, twists and pleats made the thread material truly eye-catching in a full inlay. The gauge of the design threads was just as varied as their appearance. Rough representatives had thicknesses of up to dtex 5,500, while the most delicate had a thickness of dtex 500.

Perfect machine running across all effect yarns

As the focus of the processing tests was on effect yarns, a simple pattern was chosen for the base fabric. Ground guide bar GB 1 ensures high longitudinal stability with a pillar stitch. GB 2 implements an inlay under two needles. This resulted in a voile-like, structurally stable textile with a dense surface but sufficient transparency for a conventional curtain article. The discreet view through was achieved by using a machine gauge of E 24 and a high yarn gauge. Polyester dtex 50 f 24 was used in both ground guide bars.

All of the 36 decorative threads used could be easily integrated into this fabric base. Neither the machine speed nor the fabric appearance had to be compromised. “Even with variants where we had reservations, for example because of the yarn thickness or design, we reached our target of 1,500 rpm on the machine,” says Jürgen Wohlrab from Karl Mayer’s Textile Technology Product Development department.

Perfect quality was also achieved by balancing the stitch density, yarn gauge and feed distance. Thin threads must be firmly bound into the ground by a higher number of stitches per cm. Otherwise they can just be pulled out, based on Jürgen Wohlrab’s experience. In contrast, thick, heavy and fluffy effect yarns require a low stitch density to prevent the pattern thread from pinching or even the basic structure from bursting. This correlation between stitch density and yarn gauge becomes less important as the number of weft threads per unit length decreases. During KARL MAYER’s processing tests, a decorative thread was registered approx. every 1.5 cm. In view of the large spacing, the stitch density — adjusted to 18 stitches/cm — could be kept constant.

Further design potential for the fabric ground and effect yarns

Pattern yarns not only render sophisticated design effects possible thanks to their diverse constructions, but also by playing with the yarn tension during integration. For example, base fabrics with taut, fluffy variants can spring into place after being removed from the machine and thus form a striking crepe-like surface. Jürgen Wohlrab wants to test this in further investigations. He also wants to use the patterning possibilities of three-bar tricot machines, which the WEFT.FASHION TM 3 offers in principle, to design new base fabrics. It would be conceivable, for example, to produce textile structures with lengthwise stripes of varying density by using a mesh treading. Used crosswise, it could be used to create striking base curtains.

Through the targeted variation of threading, yarn selection and textile construction, it is also possible to open up applications beyond the curtain sector, e.g. for upholstery and clothing, such as light blouses, dresses or trousers.

A specialist in producing warp knitted home textiles

The WEFT.FASHION TM 3 is an efficient tricot machine with course-oriented weft-insertion for producing medium-weight home textiles. The basic equipment includes three ground guide bars and a system for inserting up to 24 weft threads. These are delivered from a creel and laid across the entire working width. The guide bars are controlled by pattern disks.

The machine delivers an exceptional cost-to-benefit ratio, runs extremely reliably, and is easy to operate. It is available in a gauge of E 24 with a working width of 132”. Its product portfolio includes warp knitted curtains with incorporated effect yarns, maximum 3.25 m in length and imitating woven material. Unlike weaving, warp knitting does not require a sizing process, nor the corresponding use of water, chemicals or energy. Productivity is also excellent. On the WEFT.FASHION TM 3, depending on the article being produced, up to 60 m of curtain fabric can be produced per hour.

Posted June 8, 2021

Source: Karl Mayer

OBERTSHAUSEN, Germany — June 7, 2021 — Tough times call for soft, comfortable outfits, and wide-cut clothing made from soft fabrics, with textures that promise a feeling of cosiness thanks to a voluminous look, are flourishing and inspiring creative minds.

The textile product developers at Karl Mayer were also inspired by the trend towards “stay-at-home” wear that also provides a feel-good guarantee. They have created a collection of lightweight warp knitted textiles that brought chic to home wardrobes with a multiform crinkle-effect look and bright colors, but that will also cause a stir on the streets and at parties in post-coronavirus times. Karl Mayer’s newcomers include dense fabrics with small repeat waffle or wave patterns, seersucker makes or origami-like designs, as well as transparent fabrics on which curved architectural lines stand out like veins.

The play on opacity and transparency brings extravagance and allure to any outfit, as demonstrated by the delicate blouse on this page. Light warp knitted textiles with a plastic wave design and a cut featuring playful trumpet sleeves and sexy slit neckline create an extremely feminine piece suitable for almost any occasion.

The on-trend textile was produced on a HKS 4-M EL in E 28. To implement the 3D effects, the universal high-performance tricot machine has processed a polyamide wrapping yarn with elastane cores. Various lappings make different elastic properties and patterns possible with the same threading. In addition to high flexibility, the HKS 4-M EL offers maximum efficiency. The extraordinary design variety combined with a high working speed makes the HKS 4-M EL the machine of choice when it comes to manufacturing short runs and developing new products.

More information about the fashionable items with a crinkle-effect look made on an HKS 4-M EL will be available on the KARL MAYER Group’s exhibition stand at ITMA ASIA + CITME, 12 to 16 June, A 35/Hall 4 at the NECC Shanghai.

Posted June 8, 2021

Source: Karl Mayer

REUTLINGEN, Germany — June 6, 2021 — Just like the fashion sector, the shoe industry is driven by short collection cycles and enormous pressure in terms of time and cost. In order to make processes faster and save on labor, two medium-sized German enterprises — KARL MAYER STOLL Textilmaschinenfabrik GmbH and DESMA Schuhmaschinen GmbH — have joined forces for a joint project. The two partners are confident that combining their specialisms at every stage of the shoe industry’s global value chain is an opportunity that promises plenty of potential for optimization. “This innovative shoe model provides the perfect example of how we can manufacture complex products with a high degree of efficiency and sustainability, by working together and harmonizing our companies’ process sequences,” said Andreas Schellhammer, head of Business Unit STOLL at the Karl Mayer Group.

Diversity, efficiency and sustainability

The two partners have developed an integrated solution that enables innovative shoe models to be manufactured using a highly efficient process. The process starts with the production of seamless, 3D-knitted uppers, which are then hardened in order to activate the functional yarns woven into them, before being attached directly to dual-layer sole constructions.

The advantage of this method is that it minimizes lead times in the development and production process and allows the machine settings to be adjusted for optimum product quality without any additional investment. The machine technologies used for the process — STOLL flat weft knitting and DESMA direct sole attachment technology — are already in widespread use in the shoe industry, for both innovative new products and mass production. Most significantly, the new solution reduces the number of time-consuming production steps required, such as making up the uppers and manually joining together uppers and soles made from different components. It is also a sustainable innovation, as the seamless manufacturing technique means there is no scrap or waste, so no resources go to waste. In addition to this, a seamless, 3D-knitted upper is more comfortable to wear as it is shaped to provide the perfect fit. Last but not least, productivity and pioneering design considerations have also been factored perfectly into the process. Thanks to the flat weft knitting machine and efficient sole attachment process, it is now possible to manufacture high-performance footwear with custom designs using industrial processes.

All-in-one solution for custom uppers

The footwear is manufactured using the ADF 330-32 ki BcW flat weft knitting machine. Like all ADF machines, this model interacts with a number of different knitelligence® components to provide an efficient, automatic and fully digitalised production process. It can also handle a huge variety of different designs. With technology such as inverse plating, STOLL-ikat plating® and STOLL-weave-in® Technology, it can incorporate a wide range of knitwear looks and all the components of the upper directly into the fabric, thus speeding up the making up process. This enormous design potential can be expanded even further by using the multi-gauge E 9.2, in keeping with current trends in the textile shoe upper market. The fabrics created using this process boast designer textures with a level of detail never seen before in flat weft knitted uppers and with on-trend non-porous surfaces. What’s more, the textures of the stitching in the fabric are almost imperceptible. In terms of design potential and the advantages for the making up process, the technologically driven innovations make the ADF 330-32 ki BcW, E 9.2 extremely appealing for any major player in the shoe industry. In addition to this, the ADF machine is also notable for its 36″ working width and optimized dimensions, which represent an added bonus in terms of efficiency. It is also possible to convert any existing ADF flat weft innovation. Besides the production method, its compact format makes this the perfect solution for design and development processes — and thus for tapping into new markets.

More information on the joint venture with DESMA will be available at the Karl Mayer Group’s exhibition booth at ITMA ASIA + CITME, Hall 4/A 35 at the NECC Shanghai between June 12-16, 2021, and on the STOLL website from June 12.

Posted June 8, 2021

Source: Stoll/Karl Mayer Group