#Weaving

2024-11-28

Innovations for warp preparation at the cutting edge

At ITMA ASIA + CITME in October, KARL MAYER presented solutions for lower production costs and environmental impact and greater efficiency in the warp preparation sector. After the trade fair, the company can draw a positive conclusion, both in terms of the number of visitors and the quality of the discussions.

The KARL MAYER Warp Preparation Business Unit draws a positive conclusion after ITMA ASIA + CITME 2024 © 2024 KARL MAYER

In addition, the overall presentation was right on target. As at every ITMA, the KARL MAYER stand was a meeting point for the industry. “In a market that is increasingly characterised by Chinese competitors and price pressure, we have demonstrated our strong presence,” says Dieter Gager. The Vice President Sales & Marketing at KARL MAYER’s Warp Preparation Business Unit and his team negotiated numerous projects and discussed upcoming investments in the course of the trade fair. Many manufacturers want to expand or modernise and are gathering information, but are waiting for a recovery in global demand, according to Dieter Gager's assessment. When the market picks up, they will benefit from their knowledge of the innovations presented at the trade fair.

One of the highlights was the WARPDIRECT, a latest-generation warping machine with an excellent price-performance ratio. The possible warping speed is an unbeatable 1,200 m/min. The quality of the beams produced is also unrivalled. Thanks to the high level of quality, yarn waste can be saved during the sizing process and the efficiency of the downstream weaving process can be maximised. Other advantages include high operational reliability and less maintenance work. With this performance, the WARPDIRECT attracted the attention of trade fair visitors from Pakistan, Bangladesh and other countries neighbouring China.

Visitors were also interested in two innovative solutions for sizing with advantages when using the PROSIZE®.

The brand new CASCADE system reduces steam consumption by up to 7% thanks to intelligent steam recycling within the machine. This enables significant savings in energy costs and CO2 equivalents over the entire utilisation cycle of the machine and not as a one-off effect.

The second innovation in the group of novelties relating to sizing is the Smart Size Box. This sophisticated technology uses sensors and digital solutions to monitor the condition of wear components, making a valuable contribution to predictive maintenance. The customer can plan interruptions due to maintenance work in advance, avoid uncalculated downtimes and fully utilise the performance potential of the PROSIZE®.

The highly efficient sizing machine operates at a speed of 160 m/min, with 200 m/min possible as an option. With a yarn cover factor of up to 100 % - 20 % more than conventional systems - a high sizing quality is achieved and the range of applications is extended.

The feedback at the trade fair on the Size Box with the big plus in customer benefits was encouraging. “By focusing our development activities on maximum machine availability and digital solutions, we have hit the nerve of the times,” says Dieter Gager.

To ensure high machine availability, a combined Care X-Tend and Connectivity package was also presented at the trade fair. Among other things, the package provides easy access to fast remote assistance. Unlike conventional teleservice support, images and large amounts of data can now be exchanged easily and securely, minimising interruptions to operations.

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.

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.

Fewer pores, greater impact tolerance: Peter Dornier Foundation Prize 2026 honours material research on fibre-reinforced composite components for aerospace industry

Microscopically small pores that form during manufacture, or barely visible impact damage, can severely impair the load-bearing capacity and service life of fibre-reinforced composite components. Two young researchers have presented groundbreaking work in this field and will both be awarded the 2026 Peter Dornier Foundation Prize: Dr.-Ing. Benedikt Neitzel from the Technical University of Ilmenau for his doctoral thesis on pore minimisation in the RTM process, and Johanna Buschmann, M.Sc., for her master’s thesis, completed at the German Aerospace Centre, on the improved impact tolerance of 3D fabrics compared to 2D laminates.

Itema reaffirms its commitment to the Syrian textile industry at NasTex 2026

From July 18th to 21st, Itema will exhibit at NasTex at the Damascus Fairground (Hall 11 – Stand C02), marking its return to one of the Middle East’s historically significant textile markets. Itema will showcase advanced weaving technology designed to support the competitiveness and technological evolution of Syrian manufacturers and announces a new partnership with Growfast Agency as the sole agent of Itema in Syria.

BASF opens global diaper and superabsorbents performance lab in Mumbai

BASF has officially inaugurated its new Performance Lab for diapers and superabsorbents (SAP) in Mumbai on August 18, 2026, which will provide technical and application services to superabsorbent customers globally. The new lab of BASF’s Hygiene Solutions business has been established in less than a year and is part of BASF’s Innovation Campus Asia Pacific in Mumbai, BASF’s second largest R&D site in Asia Pacific established in 2017 under BASF Chemicals India Private Limited.

Naia™ from Eastman strengthens western hemisphere textile connections at Apparel Sourcing Show Guatemala

As brands and retailers explore more diversified and responsive sourcing networks, the Naia™ brand from Eastman is strengthening its engagement with the textile and apparel value chain across the western hemisphere. From August 18–20, the company will participate for the first time in Apparel Sourcing Show Guatemala, a regional meeting point for apparel sourcing, manufacturing and nearshoring.

Dornbirn GFC 2026 expands conference program with new thematic sessions

For 65 years, Dornbirn GFC has stood for innovation and is one of the world’s leading conferences in the fiber industry. From September 16 to 18, 2026, the international fiber community will meet in Dornbirn, Austria, to discuss current trends, technological developments, and forward-looking solutions. More than 600 experts from industry and academia from over 30 countries are expected to attend. With around 100 presentations by renowned speakers, a 2,5-day conference program, and three parallel presentation rooms with moderated sessions, Dornbirn GFC provides a first-class platform for knowledge exchange, networking, and international collaboration. Together, participants will generate ideas and impulses that will sustainably shape the future of the global fiber industry.

Europe is committed to recycling end-of-life wind turbine blades

Starting in 2026, Europe’s wind energy industry has committed itself to ensuring that wind turbine blades do not end up in landfills once they reach the end of their service life. The EU-funded research project REWIND is exploring ways to reuse this composite waste. The German Institutes of Textile and Fiber Research Denkendorf (DITF) are one of 13 project partners from seven countries.