#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If the machinery is becoming outdated, investments in targeted upgrade offers are an interesting alternative to cost-intensive new purchases for many manufacturers, especially in difficult economic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 After years of use, the mechanics are usually still in good condition, but the electrics are outdated after regular generational changes.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.

Driving WARP KNIT Inspiration

KARL MAYER sees performance fabrics and next-level textile solutions in particular as potential growth drivers for its customers, as a motor for business development and as real game changers for the entire textile industry. Innovation does not happen by chance. It is the result of close exchange with customers & brands, textile expertise and competence in textile machine engineering. This is why KARL MAYER is investing in progress and collaborative development and opening its TEXTILE INNOVATION CEN-TER (TIC) – a place to be for the entire textile world.

KARL MAYER (China) celebrates its 30th anniversary

On February 6, KARL MAYER (China) celebrated the new year and its 30th anniversary. Employees and the management team at the Changzhou location, as well as representatives from management in Germany, Italy, and Hong Kong, were invited to the festivities. A special highlight was the visit by Lutz Wolf, CEO of KARL MAYER.

KARL MAYER at JEC: Multiaxial reinforced CFRP pultrusion profiles are picking up speed in the mobility sector

KARL MAYER Technical Textiles will be showcasing exciting new application potentials for multiaxial non-crimp fabrics in combination with the pultrusion process at the upcoming JEC in Hall 5, Booth C 46. The advancement of the tried-and-tested pultrusion process enables the cost-efficient production of complex CFRP multi-chamber profiles, which are used in the CETROVO high-speed metro. The world's first carbon-intensive lightweight rail vehicle of this type is designed for speeds of up to 140 km/h.

Huixing acquires insolvent Mayer & Cie.

Insolvency proceedings for the circular knitting and braiding machine manufacturer Mayer & Cie. were opened on December 1, 2025. Immediately following the opening of proceedings, the complete cessation of business operations was initiated. Most employees were subsequently given notice effective the end of February 2026. The production of the remaining orders in the circular knitting segment is expected to be completed by the end of the month. As early as December 2025, Mayer & Cie.’s braiding machine division was sold to an Italian investor.

SHIMA SEIKI to exhibit at GMMSA Expo India

Leading Japanese computerized flat knitting technologist SHIMA SEIKI MFG., LTD. of Wakayama, Japan, together with its Indian sales representative Universal MEP Projects & Engineering Services, Ltd., will participate in the upcoming Garments Machinery Manufacturers & Suppliers Association (GMMSA) Expo India 2026 exhibition to be held in Ludhiana, India next month. Through its lineup at GMMSA, SHIMA SEIKI aims to further strengthen its presence within the Indian market with an exhibit that caters to diverse needs, consisting of seam-free WHOLEGARMENT® knitting technology as well as a brand-new shaping machine with high productivity and excellent cost performance.

KARL MAYER opens a new TEXTILE INNOVATION CENTRE – a new era of textile innovation begins

KARL MAYER is opening its new TEXTILE INNOVATION CENTRE (TIC), sending a strong signal that it is driving textile innovation forward and opening up new perspectives for the textile industry. The TIC brings together the latest developments in Warp Knitting, Technical Textiles and Warp Preparation – KARL MAYER’s core areas of expertise.

Knowledge that drives progress: Techtextil and Texprocess forums strengthen the global textile industry with a future-oriented programme

From AI-supported production optimisation and digital manufacturing solutions to circular technologies and bio-based high-performance materials: the Techtextil and Texprocess forums provide answers to the key challenges of the global textile industry with a curated content programme. As hubs for innovation and knowledge, they enhance competitiveness and offer orientation in changing markets. From 21 to 24 April 2026, Frankfurt is once again the global meeting point for thought leaders from industry, research and business.

Enhanced protection without added weight: Innovative technology for flame-retardant textiles doubles reaction time and ensures high wearing comfort

Flame-retardant textiles have long faced the same dilemma: the higher the level of protection, the greater the compromise in comfort, weight and breathability. This is especially important for workwear and protective clothing worn for long hours, where comfort is crucial to wearer acceptance and satisfaction. At Techtextil 2026 in Frankfurt, Swiss company Textilcolor AG will unveil pyroshell™, an innovative flame-retardant technology designed to tackle this challenge. Protection is provided by a graphite-based functional layer integrated into the textile structure, which doubles the reaction time before burns occur while significantly enhancing comfort. The material does not release any toxic fumes and offers textile manufacturers entirely new opportunities to design and produce protective and functional garments. It is also durable enough to withstand up to 50 industrial washes.