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20th July 2016, Obertshausen

Karl Mayer presents warp preparation machine for direct and sectional warping

Karl Mayer, a leading warp knitting machinery manufacturer, will present its new DS Opto-EC innovative warp preparation machine at ITMA ASIA + CITME that will take place in China, in October.

The machine combines sectional warping in weaving preparation with direct warping in warp knitting preparation on the basis of a universal hybrid principle. The result of this combination is said to be maximum flexibility and economic viability when producing warp beams for warp knitting.

Overall view of the DS Opto-EC. © Karl Mayer

The operating principles and advantages of the DS Opto-EC were presented to the public for the first time at ITMA 2015. By watching a video presentation and by talking to Product Manager Krishna Adhikari, visitors were able to gather information about the new technology and the company’s product developers were delighted with the positive feedback.

Direct and sectional warping

The DS Opto-EC processes non-stretch filament yarns to produce warp beams having a wide band width. Conventional sectional warp beams with long running lengths, having a width of 21” and a diameter of 30", can be produced efficiently by the direct warping process, according to the manufacturer. If short warps are needed for product development, the DS Opto-EC is said to offer easy handling and low costs in the sectional warping mode. Furthermore, the warp-for-warp technique is designed to enable processing tests to be carried out on expensive yarns economically.

Warping carriage for accurate positioning of the yarn sheet on the warping drum. © Karl Mayer

The DS Opto-EC also offers advantages for cone warping when producing patterned sectional warp beams, the company reports. This machine places yarn sections of different colours next to each other accurately, and operates at high speed, thus producing precision warp beams efficiently.

According to Karl Mayer, this is opening up new possibilities in the warp knitting sector, especially in terms of the range of patterns that can be produced. The HKS 4-M EL was illustrating these possibilities impressively at ITMA 2015 in Milan.

HKS 4-M EL and DS Opto-EC

The HKS 4-M EL was processing patterned sectional warp beams produced by the DS Opto-EC when it was being demonstrated at ITMA 2015. During the machine show, this high-speed tricot machine was producing a fabric having six different, attractive designs seamlessly one after the other – without stopping and at top speed.

Patterned sectional warp beams on the HKS 4-M EL. © Karl Mayer

The HKS 4-M EL was operating at an average speed of 2,100 min-1. The EL pattern drive on this innovative machine enables the pattern to be changed quickly, and virtually unlimited repeat lengths can be worked, the company explains. The combined performance of the HKS 4-M EL and the DS Opto-EC is said to enable new products to be developed economically, if required.

High performance

As well as being flexible, the DS Opto-EC also aims to offer top quality in both warping modes, and enable warp knitting to be carried out at maximum efficiency. The sectional warp beams have absolutely identical circumferences, and the package build is completely uniform. This unique level of precision owes its success to the improvements that have been made and to technology transfer, the company reports.

Dancer rollers for controlling the yarn tension during beaming. © Karl Mayer

For example, the master successive band or master successive beam principle, which is a feature of weaving preparation, has been transferred to the DS Opto-EC, and the conventional sectional warping process has been optimised. The creel system, yarn feed and braking synchronisation are all coordinated during cone warping. A warping carriage, which moves parallel to and across the drum axis, is designed to guarantee exact positioning of the yarn sheet on the warping drum, and the band build-up is monitored by a laser and computer.


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