KARL MAYER Textilmaschinenfabrik GmbH
Bühlstrasse 25
63179 Obertshausen

E 50 – a new standard for gauging the fineness of warp-knitted fabrics - KARL MAYER Textilmaschinenfabrik GmbH

There is currently a high demand in the clothing and lingerie sectors for delicate, sheer, elastic knitted fabrics. These exceptionally pliable fabrics enable completely new designs to be created, offer haptic characteristics that have never been achieved before, and promise continuing lucrative business – a trend that has encouraged warp and weft knitters to develop fabrics in extremely fine gauges. KARL MAYER’s new HKS 2-3 E machine is setting new standards in the production of super-fine textiles. This new machine operates at a record gauge of E 50 and its technical features enable it to produce the finest warp-knitted stretch fabrics in the world. The basis for this exceptional achievement is the clever way in which tried-and-tested components for processing elastane have been combined with specific new innovations. The knitting elements in particular were completely redesigned for operating at this particular needle gauge to enable them to process extremely fine yarns. Elastic fabric batcher no. 29 B: The HKS 2-3 E provides controlled relaxation and handles the fabric so that felting and tension variations are eliminated. To do this, the machine was equipped with the elastic fabric batcher no. 29 B. The standard fabric batcher no. 34 A or AE, which is also suitable for taking-up stretch fabrics, was not used because its friction-driven ascending batch winder cannot handle the textile gently enough. When producing very fine articles, the increasing roll weights may often cause felting and stitch distortion. On the other hand, type no. 29 B operates with a central winder equipped with an active drive. The speed of the shaft is adapted to suit the increasing roll diameter by means of an automatic, fabric-tension-controlled speed regulator – an expensive but reliable solution, especially when taking-up very fine fabrics, which also guarantees a uniform roll build-up. Another device for improving the quality of batching is the integrated spreading device. The three shafts just in front of the central winder smooth out any edges that have rolled over by means of spiral springs, thus ensuring that the roll build-up is straight in the horizontal direction. In addition to the central winder, the 29 B batcher also has a relaxation zone. This zone, which is located immediately after the fabric take-down point, reduces any inherent tension and consists of several smoothly rotating rollers for transporting the fabric. Seamless quality control: Protechna can supply the Procam camera monitoring system for use in fabric quality control. This optical inspection system was premiered at ITMA 2003, and is mainly used in the production of high-quality stretch articles and automotive fabrics. KARL MAYER has equipped its E 50-gauge HKS 2-3 E with the Procam system for this year’s ITMA trade fair.