At the upcoming ITMA in Milan, the KARL MAYER GROUP will be presenting solutions that enable its customers to master the far-reaching changes of our time and to turn their challenges into opportunities - especially when it comes to digital transformation. The group of companies supports its customers on their way into the digital world of their industries with new digital developments, which it can drive forward quickly thanks to the combined innovative power of its individual business units. When it comes to customer-specific requirements for machine technologies in warp knitting, specialized knitting, warp preparation and technical textiles, the experts in these business units are in demand. Their task is primarily to develop software and smart machine functions. The experts in the KM.ON business unit, with their overarching focus on digital solutions, have their sights set on controlling and optimizing processes.

The potential offered by the combined digitalization approach is manifold, especially for increasing efficiency.


Smart-machine functions

To maximize productivity, the KARL MAYER GROUP is specifically developing smart-machine functions that exploit the potential offered by digitalization or artificial intelligence, for example, to revolutionize pattern changing in warp knitting using cloud-based patterning. High-performance warp knitting machines of the digital generation such as the HKS 3-M ON work with pattern data from the cloud instead of pattern discs and thus offer unique flexibility: patterns can be changed at the click of a mouse on the computer and without manual intervention. In addition to the handling effort, costs and environmental pollution caused by the production, transport and storage of mechanical data carriers are eliminated. Moreover, patterns are 100 % reproducible, again without any manual adjustments.

The KARL MAYER GROUP also offers smart solutions for machine functions and processes in the flat knitting sector. The software offerings are combined in a single package and cover the entire value-added chain of the flat knitting mill by means of a fast image knitting program, individual sorting and patterning, and optimized production management. The result is a consistent, optimized workflow that makes greater productivity possible. Other benefits include faster response times, greater plant efficiency thanks to real-time transparency and lower costs thanks to overall production optimization.

Innovations focusing on the smart machine theme include a CANopen interface via which high-end storage feeders from external suppliers can communicate bilaterally with the machines. The fusion ensures reliable guidance and exact infeed of special, sophisticated yarns, thus making high-quality goods possible.


Digital solution for product development

Digital support is also available for the creation of samples. The KARL MAYER GROUP offers various software products at different levels for the design process of knitted and flat knitted fabrics. Even 3D simulations of the designed flat knitted articles are possible with the help of appropriate external software. The design and patterning tools make the customers' business easier. They provide greater flexibility, efficiency and creativity, thus helping to save costs and shorten time-to-market, and also score points in terms of sustainability, because they can be used to reduce the number of physical samples.


Digital tools for production management

Other digital solutions focus on the analysis of production data. For example, warp knitting customers will be able to use real-time information on the energy consumption of their machines in the future with a new energy monitoring system. A first prototype will be shown at the trade show. For the time being, the monitoring tool provides detailed insights into energy data in particular, which can be used to better understand production and control it for optimization.

In addition, KM.ON offers DPM (Digital Production Management), a software solution that facilitates and improves the management of a knitwear factory. With real-time insights, streamlined processes and optimal resource allocation, DPM enables data-driven decision making and flexible adaptation to market demands, helping textile manufacturers on the path to sustainable success and growth. Production planning and analysis functions, as well as live data and reporting capabilities, provide full visibility into production operations. This enables faster response times, higher productivity and lower personnel costs.

A dashboard for monitoring with real-time data on machine operation is also provided for KARL MAYER's warp preparation machines, especially for the sectional warping sector, and the STOLL PPS is a digital production planning tool for the flat knitting mill. The central platform for production data and production processes informs the customer online during ongoing operation about important events in his production. This enables fast reactions to deviations and prompt repairs for minimum downtimes. An operating calendar is available for realistic planning and evaluation of production capacity.


Care Solutions with digital offers

In line with its holistic approach, the KARL MAYER GROUP also offers its customers added value in the support sector via digitalization. For warp knitting and warp preparation, digital options such as remote maintenance have been combined with conventional offers for this purpose. The completely new service approach includes a welcome desk, a ticket system as well as first, second and third level support and offers customers fast and transparent support. It also creates the basis for predictive maintenance and servicing.

In warp preparation, networking the machines with the cloud ensures efficient access to machine data and remote service. In addition, quality management reports can be accessed on any mobile device via the cloud. Likewise, the prerequisites for a Proactive Warping cloud function are created.


Committed to the highest level of data security

The most important resource for the use of all these digitalization offerings is data. The KARL MAYER GROUP considers the data surrounding the operation of its machines to be an asset worth protecting and uses established, recognized security procedures and encryption methods to prevent unauthorized access. To ensure the highest standards of security and performance, the company pursues a connectivity strategy based on state-of-the-art KM.ON solutions.