#Knitting & Hosiery

2025-03-05

Controlling the service life

If the machinery is becoming outdated, investments in targeted upgrade offers are an interesting alternative to cost-intensive new purchases for many manufacturers, especially in difficult economic times. KARL MAYER therefore offers an electrical retrofit for its customers in the technical textiles sector. The retrofit solution brings the control and drive technology of older multiaxial and warp knitting machines with weft insertion up to the current standard, thus minimising production risks.

Maximum production reliability thanks to the electrical retrofit for KARL MAYER multiaxial and warp knitting machines with weft insertion with a long running time © 2025 KARL MAYER

“The machines are often in operation for several shifts, seven days a week. After years of use, the mechanics are usually still in good condition, but the electrics are outdated after regular generational changes. If this leads to breakdowns, the result is high costs and long downtimes. This can be avoided with our electrical retrofit,” explains Falk Preibisch from the Care Solutions Team at KARL MAYER Technische Textilien.

Short conversion times

Anyone ordering an electrical retrofit will receive a new control cabinet with a user interface and control technology from the latest generation of KARL MAYER machines. In addition, everything required for dismantling the old motors and for the new cabling is supplied. The conversion work takes around two weeks on warp knitting machines with weft insertion and around three weeks on multiaxial warp knitting machines and requires the deployment of one or two service technicians - an effort that is well worth it.

Standardised operation, improved serviceability, reliable spare parts supply

The electronics upgrade offers the customer the familiar, modern user interface of the new KARL MAYER machines and therefore maximum ergonomics, intuitive functionality and a standardised user interface. The operating personnel always know their way around immediately, regardless of the year of manufacture of the machine. The electric retrofit also scores highly when it comes to service and maintenance. The service specialists at KARL MAYER Technical Textiles, who are familiar with the modern machines, know what needs to be done and, unlike for the old systems, spare parts are guaranteed to be available in the long term. Another advantage is that the machine can be networked through targeted retrofitting.

Successful solution

The offer to modernise at minimal cost and downtime, without the environmentally harmful disposal of old machines, is generally recommended for machines built in 2000 or later.

“The electrical retrofit is now selling very well,” says Falk Preibisch, satisfied with the demand.

Since its introduction in 2016, the electronics upgrade has already been ordered around 55 times, mostly for machines that have been in operation for between 15 and 25 years.

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.

More Jacquard. More functionality. More fashion.

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.

KARL MAYER's HKS 2-SE Expands Possibilities for Premium Stretch WARP KNITS

Warp knitted fabrics with a woven look are more in demand than ever in the fashion and apparel industries. Stretch WARP KNITS, in particular, impress with their freedom of movement, breathability, and virtually wrinkle-free wear – thereby opening up new style worlds such as smart casual or business casual. When it comes to the highly efficient production of premium-quality stretch WARP KNITS, the HKS 2-SE has long been the machine of choice. KARL MAYER’s best-selling tricot machine produces standard elastic fabrics characterized by high gauges, smooth, delicate surfaces, and a soft hand feel.

Footwear innovation enabled by warp knitting technology– insights from New Balance

The future of the athletic shoe is increasingly being shaped on warp knitting machines. For KARL MAYER, the footwear industry is one of the most important growth markets – and one of the sectors where innovative textiles can realize their full potential. In his keynote address at the opening of KARL MAYER’s TEXTILE INNOVATION CENTER in Obertshausen in April, Vishnu Prakash Muthusamy, Senior Textile and Materials Engineer at New Balance, explained the opportunities that warp knitting technology opens up for performance, sustainability, and faster development processes, and why textile manufacturers are transitioning from suppliers to development partners.

ITM 2026: Mayer & Cie. Global presents itself successfully at international industry trade fair

Mayer & Cie. Global has used ITM 2026 in Istanbul for its first major international appearance since the restart. Together with the Turkish representative Mayer Mümessillik, the company presented its premium circular knitting machines "Made in Germany", explained its future positioning within the group of companies and held talks with customers and representatives from numerous markets. The response to the restart was positive. The clear orientation of the company, the reliable worldwide network of representatives and the resumption of service and spare parts supply were welcomed by customers.

Ministry of Industry Delegation visits NatureWorks’ second global manufacturing site at Nakhon Sawan Biocomplex

NatureWorks Asia Pacific Limited welcomed a high-level delegation led by Mr. Varawut Silpa-archa, Minister of Industry, to its manufacturing site at the Nakhon Sawan Biocomplex (NBC). The visit follows the successful inauguration of the site on April 29, 2026, and highlights the role of public-private collaboration in advancing Thailand’s sustainable industrial development and bioeconomy ambitions.

Indorama Ventures advances circularity tthrough PETValue Philippines' “Zero Waste to Landfill Partnership” with Republic Cement

Indorama Ventures Public Company Limited, a global sustainable chemical company, is advancing the circular economy through a new Zero Waste to Landfill initiative at its recycling site PETValue Philippines, further demonstrating how collaboration across industries can maximize resource efficiency and reduce waste.

Networking Day 2026: Industry stakeholders unite around textile recycling

In 2026, the Industry Research Group (IRG) Polymer Recycling once again brought together some of the key stakeholders in textile recycling for its annual Networking Day. This year, the event took place at EREMA’s premises in Ansfelden, Austria. It brought together key players from across the textile recycling value chain for a day of structured exchange and in-depth discussions.