German warp knitting machine builder Karl Mayer says that it sees huge potential in the market for seamless products and the company is consolidating and extending its expertise in this area, as well as stepping up its R&D efforts in the seamless field. 

The company says that its DJ 4/2, 44 inch seamless double needle bar raschel machine has made quite a name for itself worldwide. “It is seamless in terms of the style of products it can produce, and smart thanks to its performance”, the company says. The machine was launched in the third quarter of 2008 and since then it has proved to be a real success story for many of the German company’s customers.

Meanwhile Karl Mayer has been busy extending its seamless range of machines. The DJ 6/2 (EL) 44 inch, a new sister machine for the DJ 4/2 was recently unveiled at the Shanghaitex 2009 trade fair. The new machine is based on the successful, compact, narrow DJ series, and is available in gauges E 24 and E 28, gauges that have also recently been introduced for the DJ 4/2. The DJ 6/2 has four ground guide bars, two more than its sister machine, which is already in the market, and can be fitted with the company’s EL, electronic guide bar drive. Karl Mayer says that these features have considerably extended the range of patterns that can be produced and improved the machine’s flexibility. The DJ 6/2 (EL) can produce a range of seamless or virtually seamless articles, from pantyhose and stockings to underwear and sportswear.

Karl Mayer also says that the EL system enables patterning to be carried out with a high degree of flexibility, and even small batches can be processed extremely efficiently. “This greatly simplifies the processes involved in product development. Especially pattern collections can be made up with minimum effort. Large repeats can also be worked, enabling completely new products to be produced”, the company says.

In addition to the EL system and additional two ground guide bars, Karl Mayer says that the tried-and-tested patterning elements can produce a wide range of different designs required when producing seamless products. A jacquard system with two jacquard guide bars, piezo technology for control of the jacquard needles, the Kamcos system with Multi-Speed facility and electronic beam drives enable the customer to produce high-quality, jacquard-patterned, seamless clothing or garments with fewer seams efficiently on one machine.

Karl Mayer’s RSJ 5/1 EL raschel machine has already been showing the development potential offered by the combination of the EL system and the jacquard bars for producing stretch warp-knitted fabrics. The company says that in simple terms, when considering the patterning principles, two RSJ 3/1 machines could be placed back-to-back to form a single DJ model.

The RDPJ 6/2, 138" is another seamless production alternative, which is particularly suitable for processing large batches, Karl Mayer says. This double needle bar raschel machine is complemented by the compact, high-speed DJ series. Karl Mayer claims that manufacturers are extremely impressed by this concept.

“The number of orders has been better than expected since the DJ series was introduced. In the light of the current economic situation, companies are trying to improve their competitive edge by coming up with new ideas and trying new approaches. Our DJ 6/2 can help them to do this”, says Sales Manager, Oliver Mathews.

“The new DJ series, with its high performance potential, is a welcome starter model – for knitting companies looking to break into new areas of business, as well as for producers of seamless articles in search of new, innovative technologies”, Mr Mathews added.

Andreas Feuerbach has been appointed as Sales Manager to coordinate the company’s operations worldwide.

Download Karl Mayer’s Seamless Smart catalogue (English/ Chinese