Streetart on the beach
Warp knitted terry fabric with digital prints for even more bathing fun

Towels are not only useful for drying off, but they can also steal the show from bathing beauties. You only need to look at the extravagant example on this page to see how. The terry cloth product produced by KARL MAYER creates vibrant accents with lively motifs in bright colours no matter whether you are around the swimming pool, at the beach or even simply next to the washbasin in the bathroom.

Terry Towel Grafitti

The textile was produced on a TM 4-TS EL with double-sided fabric to ensure that the finished product is not only a must-have bathing accessory, but also a real eye-catcher. One side features a dense layer of cotton loops. It quickly absorbs moisture from the skin after bathing and nestles gently against the body.

The other side consists of sheared polyester. Its soft texture invites you to relax, while its smooth finish makes it both easier to print on and quicker to dry. The imaginative design was created at ZIMMER AUSTRIA using a digital printing process.

The specialist for printing, coating and finishing systems did a great job. KARL MAYER’s textile developer, Melanie Bergmann, couldn’t be happier with the results: “The colours are extremely vibrant and vivid while the contours are sharp. Even the finest lines are clearly defined,” says the textile engineer.

Warp knitting technology with a firmly integrated terry loop ensures that the colourful towels can be enjoyed for a long time to come. The fluffy fibre layer is extremely resistant to thread pullers. The long service life and ecological advantages in production distinguish warp knitted terry articles from their weaving counterparts. The TM 4-TS EL does not require compressed air like conventional airjet rapier looms and therefore consumes around 87 % less energy per kilogram of fabric produced. The sizing process is also eliminated in warp knitting. This saves textile chemicals, waste water and energy to the tune of approx. 0.20 USD/kg. This corresponds to about 30 % of the manufacturing costs – excluding yarn – for the production of the raw material. Apart from saving costs, the terry warp knitting machine is extremely efficient. With a width of 186” and a speed of 800 rpm, the TM 4-TS EL produces around 1,800 kg of terry cloth weighing 400 g/m2 every day in 24-hour operation. This is around 250 % more than on an airjet rapier loom.

Sunny prospects with the RJ 5/1 N
Seamless chic swimsuit demonstrates the performance of the new RASCHELTRONIC®

KARL MAYER is continually adapting its RASCHELTRONIC® range to the needs of the market. With adjusted performance profiles, the efficient raschel machines are intended to give customers the edge in their usually dynamic business fields.

It was only at the end of last year that the manufacturer launched a highly productive model, the RJ 5/1 N, which sets trends in the production of chic lingerie articles and inelastic, lace-like fabrics. Now stylish swimwear from KARL MAYER’s Textile Product Development department shows the potential of this five-bar newcomer. The RJ 5/1 N can be used to produce typical RSJ articles, such as locknit produced with three guide bars, SpotNet qualities and elastic or rigid Powernet qualities, and to create effective seamless constructions. Front and back parts are produced directly on the machine, into which opaque areas and open pattern parts are alternately incorporated as required and even lettering is seamlessly incorporated. Appropriately designed leg, neck and back cut-outs can also be integrated and do not require seams thanks to the free-cut design. Only the side seams need to be closed as part of the confectioning process.

However, it is not only the making up that is efficient, but also the textile production itself. The RJ 5/1 N reaches a maximum speed of 1,100 rpm and is therefore just as fast as the previous five-bar RASCHELTRONIC®, the RSJ 5/1. The finished fabric for the swimsuit developed by KARL MAYER was produced at a speed of 12.8 m/h. Like the RSJ 5/1, the new raschel machine also works with four ground bars and one split jacquard bar. The patterning is done by a standard N gear. It is also offered in gauges E 28 and E 32. However, the RJ 5/1 N, which is produced at KARL MAYER (CHINA), is superior to the established model in terms of its price performance ratio. “The RJ 5/1 N is up to 60 % better than the RSJ 5/1 in terms of investment per production. We expect that it will become established with customers in the five-bar RASCHELTRONIC® sector,” says Sascha Müller, Product Owner Local Lace & Raschel at KARL MAYER.

Elastic yet still recyclable
Polyester-based tricot fabric with elasticity – a new development from KARL MAYER

The textile industry is responsible for huge mountains of waste in Europe: in Germany alone, 390,000 tonnes of textile waste are produced every year. Only Italy tops this figure with almost 466,000 tonnes per year, as shown by a study on waste disposal behaviour in 15 EU countries commissioned by the fashion label Labfresh. According to further study results, every German person produces 4.7 kilograms of textile waste, of which only 0.5 kilograms are recycled and 0.4 kilograms are reused without treatment. The rest is incinerated or dumped.

A key reason contributing to the low recycling rate is the purity of the material. Many clothing textiles consist of fibre or yarn mixtures that cannot be separated for the treatment process or can only be separated with great difficulty. If, for example, discreet comfort stretch for the clothing sector is required, KARL MAYER’s new fabric offers an ecological alternative.

The textile is made from yarns of different polyester polymers: a semi-dull version for a soft look and a bicomponent fibre that offers moderate mechanical elasticity with a well-thought-out structure.

The elements of the stretchable fibre consist also of different polymers and show different shrinkage behaviour: when heated, a spiral crimp is formed. As the bulky deformation is not mechanically induced – unlike in textured yarns – it produces a more permanent and pronounced elongation in comparison.

The two polyester yarns were processed into a dense fabric on a high-performance HKS 3-M tricot machine in gauge E 32. The fabric weighs 202 g/m². It stands out thanks to its dense, rich feel and a heavy drape. Clothing made from it is comfortable to wear, easy to wash, does not need to be ironed and can be recycled – after removing accessories such as buttons and buckles.

For more details, please contact:

Press release

Postanschrift / post address:
KARL MAYER Gruppe
Industriestraße 1
63179 Obertshausen

Media contact

Ulrike Schlenker
Tel.: +49 6104/402-274
E-mail: [email protected]
https://recyclingportal.eu/Archive/53525