WA R P P R E PA R AT I O NCOMPLETE SOLUTIONSFOR YOUR Success
IN WEAVING

Shirting / Sheeting / Denim / Home Textiles / Wool
/ Silk / Filament / Technical Textiles / Glass

2nd Edition

kARL MAYER WARP PREPARATIONWARP PREPARATIONCOMPLETE PROCESSSOLUTIONSWarp Preparation Karl Mayer

Zero defect and 100 %capacity utilization
One of our main objectives is to ensure that your weaving mill produces at thehighest efficiency. We are the only manufacturer in the world who offers
complete process solutions for the warp preparation business. Therefore weoffer you the highest reliability for economic efficiency, quality and flexibilityof your weaving factory.
Since 1991 we, as market leader, have been providing our customers withsustainable concepts. Innovative technology and reliable service structures
guarantee the durability of your machines. KARL MAYER has agencies allover the world, at our customers‘ locations. Our global service network
provides you with quick and targeted service solutions. Pre- and aftersales
concepts support the long service life of your equipment and processes.
Our integrated processes ensure zero defect and 100 % capacity utilization
for your machines during production. Our Centers of Excellence develop
special solutions for your complete business activities. We can also offer
you tailor-made development solutions for your special requirements.
With our ground-breaking innovations we are always one step ahead. This
competitive edge is the result of our professional development management
and of our excellent relations to textile and technical colleges and universities. Our technology leadership also becomes evident by numerous applications of innovative patents.
This leaflet shows you our entire product portfolio and the appropriatetechnical solutions. Please kindly contact us if you have questions regarding
your individual issues and wishes. Our experts are looking forward to meeting
you and having a personal conversation with you. They would be pleased tohand you over detailed technical folders for your specific requirements.
We are looking forward to hear from you!

kARL MAYER WARP PREPARATION

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WARP PREPARATION kARL MAYER

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CONTENT
01 INNOvATIONS

6–7

02 COMPLETE SOLUTIONS

8 – 1103 SHIRTING

12

04 SHEETING

13

05 DENIM

14

06 HOME TExTILES

15

07 WOOL

16

08 SILK

17

09 FILAMENT

18

10 TECHNICAL TExTILES

19

11 GLASS – TECHNICAL SECTOR

20

12 GLASS – ELECTRONIC SECTOR 21
13 PRODUCT OvERvIEW

22

kARL MAYER WARP PREPARATION

06 / 24INNOVATIONSALWAYS ONE STEP AHEAD

LINk-MATIC AUTOMATIC bATCh
ChANGING SYSTEM
Full automation system to prepare beam creel by one operator. Increased productivity up to 25% and waste reduction by
450 m.

INdIGO dYEING IN NITROGEN
ATMOSPhERE
Cutting edge technology in indigo dying to increase up to threetimes pick-up dye vat at reduced water consumption

MM-32 PATTERN YARN SELECTOR MAdE
FROM CARbON ANd PATENTEd
CENTER-YARN TRANSPORT FACILITY
Increased price performance up to 30% compared to GOM-24

PROdIRECT WARPING MAChINE
User-friendly interface design for easier machine operationand insightful overview of production data. Electricallycontrolled high-precision pressure role guarantees optimal
results.

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PRO RObOT: RObOTIC ARM ON WARPINGTAbLE

WARP PREPARATION kARL MAYER

CAMERA bASEd QUALITY CONTROL

enables complete automation of warping process from fi xationof first band on drum until the warping order is completed.

Precise measurement of band width for better quality control
with digital image processing through high resolution camera
systemPRO-ACTIVE WARPING

MULTI GUARd

Cloud-based self-learning of warping process. Clearsummary of warp build-up as diagrams and presentationsof deviations with understandable coloured evaluations.

Individual yarn breakages and yarn tension monitoring.
Graphical display of yarn tension and yarn breakages
positions.

kARL MAYER WARP PREPARATION

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PROCESS OVERVIEW

bobbins

CreelsOur integrated processes ensure zero defectand 100 % capacity utilization for your machines
during production.

direct
Warping

Sectional Warping

Sample Warpingball Warpingdenim Slasher
dyeingLong Chain
beamingdenim RopedyeingWARP PREPARATION kARL MAYER

Assembling

SizingWeaving beam

Karl Mayer Warp Preparation

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Your benefit

Shirting
Tailor-made order handling
Only a made-to-measure shirt has a perfect fit. And only a made-tomeasure order handling in warp preparation for weaving guarantees
maximum quality as well as cost-efficient solutions. Regardless ofwhether you want to process raw or dyed yarns, in batches of shortor long lengths, whether you want to produce plain or striped fabrics– with KARL MAYER’s flexible machines you can always be sure to
manufacture first-class warp beams in a most efficient and favourably-priced way.

GIR-O-MATIC
MULTI-MATIC
CreelYarn tensioner

NOV-O-MATIC

PROWARP

ISOWARPWARPDIRECTISOSIZEPROSIZE

First-class quality• Shirting made of dyed or raw yarns ofoutstanding quality• Plain or striped textiles• Reproducible results in terms of density
and colour• Minimum yarn breakage rates during allprocess stages• Unsurpassed gentle yarn treatment for
first-class results• Gives your designers a vast scope to
express their creativity
Process know-how and profitability• Specialized system expertise and complete
product portfolio• Improved machines for batches of short andlong meters• Electronic control system for highest processreliability• Flexible technology for all requirements• Cross-process quality management

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Warp Preparation Karl Mayer

YOUR BENEFITFirst-class quality• 100 % reproducible quality due to automatic
process control• Minimum yarn breakage rates during allprocess stages• Unsurpassed gentle yarn treatment for
first-class results
Process know-how• System expertise and complete productportfolio• Improved machines for warp beams with
15,000 and 30,000 yarn ends
• Electronic control system for highest
process reliability• Flexible technology for all requirements• Cross-process quality management
Profitability• Permanently high productivity in warp
preparation for weaving• Minimum yarn breakage rates• High efficiency• More process reliability and higher
productivity in weaving• Production-supporting services such as
remote maintenance of the machines

Sheeting
More competitivenessIn times of decreasing profit margins and ever increasing competition
you can take advantage of state-of-the-art machines offering highest
efficiency, thus, being the decisive basis for more competitiveness.
Successful weaving mills rely on KARL MAYER’s machines. No matter
which raw materials are used and which specific products and qualities
are to be achieved, KARL MAYER’s warp preparation machines ensure
reliable production cycles, consistent quality and the decisive increasein productivity.

GIR-O-MATIC
MULTI-MATIC
CreelYarn tensioner

NOV-O-MATIC

ISOWARPWARPDIRECTISOSIZEPROSIZE

Karl Mayer Warp Preparation

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Your benefit

Denim
PRODYE – the key to success
Denim as an “evergreen” product in the clothing sector has increasingly
developed to a sophisticated fashion article with personal touch andrapidly changing trends. Therefore, flexibility is the number one success factor for weaving mills. With its PRODYE KARL MAYER offers
you the entire denim process technology for weaving warp preparationfrom a single source. It doesn’t matter whether you decide on theslash-dyeing procedure or on the rope-dyeing method, KARL MAYER’s
PRODYE is always the most productive and economical solution.

BW
Creel

PRODYE-R

LCB

Yarn tensioner

PROSIZEWARPDIRECTPRODYE-SFirst-class quality• Extremely wide range of colours and uniquelook of your denim products• 100 % reproducible quality due to automatic
process control• Uniform yarn guiding for ensuring the bestdyeing and sizing results• Keeping the original yarn properties• Higher intrinsic value of your products forhigher profit margins
Process know-how• Outstanding flexibility• Additional components for special effects inthe dyeing process• Intelligent control system for optimum
tension control and gentle-to-yarn sizing• High-grade yarn tensioners for uniform,
lowest yarn tension• High ease of operation• Maximum protection against soiling
Profitability• 20 % more productivity in slash-dyeing• Low wastewater pollution• Highest efficiency due to reduced yarn
breakages and optimum yarn quality• Cleaning during machine operation ensues
more productivity

24 / 15

Warp Preparation Karl MayerYour benefit
First-class quality• 100 % reproducible quality due to automatic
process control• Best results thanks to uniform yarn tension• Minimum yarn breakage rates in all process
stagesProcess know-how• Specialized system expertise and complete
product portfolio• Customized, optimized machines• Production of wider warp beams of up
to 3.60 m• Electronic control system for highest processreliability• Flexible technology for all requirements• Cross-process quality management
Profitability• Profitability calculations offered by our teamof experts• More efficient processes due to highest
productivity in the long term
• Reduction of manufacturing costs• Production-supporting services such as
remote maintenance of the machines

Home textiles
Competitive edge thanks to expertise
Gain the lead and make use of KARL MAYER’s expertise to achieve afaster and more economical production with highly efficient machines.
Based on reliable profitability calculations KARL MAYER’s experts areable to offer you the ideal solution for your weaving warp preparation
business. Become more competitive by means of special solutions.
Machines of double width ensure, for example, an efficient patterningfor upholstery fabrics.

GIR-O-MATIC

MULTI-MATIC
NOV-O-MATIC
CreelYarn tensioner

ISOWARP

PROWARPWARPDIRECTZM-F

FILSIZE S/F
AMR-F
ISOSIZEPROSIZE

Karl Mayer Warp Preparation

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Your benefit

Wool
Exciting by quality
Experienced wool weaving mills know how to impress and delightsophisticated fashion labels: with exclusive quality at competitive
prices. Perfect warp preparation with KARL MAYER’s innovativetechnology is the key to success. It preserves the original propertiesof the delicate wool yarns and blended wool yarns, so that a faultlessand productive operation is possible in weaving.

MULTI-MATIC
Yarn tensioner

NOV-O-MATIC

ISOWARP

PROWARP

Process know-how• Specialized system expertise and complete
product portfolio• Improved machines for efficient warp lengths• Automatic warping with GIR-O-MATIC® and
MULTI-MATIC®, maximum precision due tospecial warping bands• Electronic control system for highest processreliability• Flexible technology for all requirements• Cross-process quality management
Profitability• Less material usage, reduced waste• Production-supporting services such as
remote maintenance of the machines

GIR-O-MATIC

CreelFirst-class quality• 100 % reproducible quality due to automatic
process control• Maximum accuracy for high efficiency• Gentle yarn treatment due to uniform yarntension• Constant, completely homogeneous dyeing
results

ISOSIZEPROSIZE

24 / 17

Warp Preparation Karl MayerYour benefit
First-class quality• 100 % reproducible quality even in case of an
unsteady nature of the raw material, due toautomatic process control• Gentle yarn treatment and protection of theoriginal yarn properties• Uniform yarn guiding for obtaining bestdyeing and sizing results• Highest quality standard with “zero defecttolerance”
Process know-how• Specialized system expertise and complete
product portfolio• Improved machines with maximum flexibility• Uniform yarn tension by means of ISOTENSand MULTITENS• Electronic control system for highest processreliability• Cross-process quality management
Profitability• Highest efficiency and maximum productivity• First-class process reliability in weaving• Reduced material usage and less waste• Lower stock reserves due to just-in-time
production• Production-supporting services such as
remote maintenance of the machines.

Silk
Special treatment for a special yarn
The prima donna amongst yarns is extremely demanding, and wants
to be given a special treat during its processing from the bobbin to theloom. This is the reason why KARL MAYER developed the ISOTENS®
and MULTITENS® yarn tensioners, a technology that guarantees auniform yarn tension during the entire process of warp preparation forweaving, at the same time compensating for an unsteady condition of
the raw material. When it comes to silk there’s no room for compromises. Therefore, rely on KARL MAYER’s machines.

GIR-O-MATIC
MULTI-MATIC
CreelYarn tensioner

NOV-O-MATIC

ISOWARP

PROWARPkARL MAYER WARP PREPARATION

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YOUR bENEFIT

FILAMENTANYTHING IS POSSIBLE
The applications of filament yarns are almost unlimited. Lightweight,
airy fashion fabrics, trendy functional garments, classical linings ortechnical textiles with particular properties – anything is possible.
Therefore, high demands are made on warp preparation for weaving.
For the special physical properties of filaments KARL MAYER can offer
the most suitable process technology. Take advantage of the mostflexible, most efficient and cost-saving solutions worldwide!

GIR-O-MATIC
MULTI-MATIC
CreelYarn tensioner

NOV-O-MATIC

PROWARPBM
ZM-F

FILSIZE S/F
AMR-FFirst-class quality• Perfect conservation of the original residual
elongation of the yarn and of its otherproperties: from the first to the last meter• Absolutely homogeneous dyeing results due
to uniform yarn tension during direct beaming• Highest process reliability in weaving due touniform yarn tension and optimum sizing
Process know-how• System expertise for all applications: fromthe finest monofilament yarns for filter
fabrics up to high-tenacity multifilaments fortire cord• Yarn guidings and yarn tensioners made from
special wear-resistant ceramics• Roller feeding devices for tension control incase of special applications• Worldwide unique regulating systems in
sectional warping, intermingling and sizing
for continuous quality assurance
Profitability• Achieving high potential savings in allprocess stages• Highest efficiency due to yarn breakages
reduced to minimum• Competitive advantages thanks to reproducible best yarn quality• Low current costs24 / 19

WARP PREPARATION kARL MAYER

YOUR bENEFITFirst-class quality• Documented processes• 100 % reproducible quality due to automatic
process control• Computer-controlled quality management
for the entire process• Wide range of materials to be used
Process know-how• Specialized system expertise and complete
product portfolio• Improved machines for especially wide warp
beams (up to 5.40 m) and high warp tensile
forces• Electronic control system for highest processreliability• Flexible technology for all requirements• Cross-process, documented quality management for all processes
Profitability• Highest productivity in all applications• High efficiency• Reduced material usage, less waste• Efficient, flexible processes with low
personnel expenses• Production-supporting services such as
remote maintenance of the machines

TEChNICAL TExTILES
PROvEN, DOCUMENTED qUALITY
very often technical textiles make great demands on the quality
management. Therefore, 100 % reproducible processes are a „must“ inwarp preparation for weaving. In this respect, a highly specialized
know-how is required because the processing widths and tensile forces
exceed the usual dimensions many times over. But by using KARL
MAYER’s machines you will be able to master these challenges without
any problems.

ZM-F
Creel

Yarn tensioner

ZM-G

BM

PROWARPPROSIZEFILSIZE S/F
AMR-F

Karl Mayer Warp Preparation

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YOUR BENEFIT

Glass – technical sector
Highly specialized complete solutions
Consistent high quality, maximum process reliability and 100 % reproducibility – KARL MAYER offers highly specialized complete solutions
for glass processing for weaving warp preparation in case of which all
the components are perfectly synchronized. In this way, you can control the complete process and can achieve unique results. KARL MAYER
is a competent partner for glass weaving mills, with many years ofexperience in the field and offering an exceptionally wide service
network.

ZM-G
Creel

Yarn tensioner

BM

PROWARPFILSIZE S/G
AMR-GFirst-class quality• 100% reproducible quality due to automatic
process control• Computer-aided quality management during
the entire process• Homogeneous degree of sizing• Precise winding structure
Process know-how• Specialized system expertise and complete
product portfolio• Improved, innovative overall solutions forhighest efficiency• Camp-cross control of all production
processes• Electronic control system for highest processreliability due to KAMCOS®
• Perfect yarn tension and circumferential
control• Cross-process quality management• Compensator-controlled assemblingmachines for the processing of very fineglass fiber yarns
Profitability• Maximum productivity and highest efficiency• Minimum yarn breakage rates• Efficient and flexible processes for all yarncounts• Production-supporting services such as
remote maintenance of the machines

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Warp Preparation Karl Mayer

YOUR BENEFITFirst-class quality• 100 % reproducible quality due to automatic
process control• Computer-aided quality management during
the entire process• Homogeneous degree of sizing• Precise winding structure
Process know-how• Specialized system expertise and complete
product portfolio• Improved, innovative overall solutions forhighest efficiency• Electronic control system for highest processreliability due to KAMCOS®
• Perfect yarn tension and circumferential
control• Cross-process quality management• Compensator-controlled assemblingmachines for the processing of very fineglass fiber yarns• ACCUTENSE 0° for the gentle deflection ofsensitive glass filament yarns
Profitability• Maximum productivity und highest efficiency• Minimum yarn breakage rates• Efficient and flexible processes for all yarncounts• Production-supporting services

Glass – electronic sector
Highly specialized complete solutions
Consistent high quality, maximum process reliability and 100 % reproducibility – KARL MAYER offers highly specialized complete solutions
for glass processing for weaving warp preparation in case of which all
the components are perfectly synchronized. In this way, you can control the complete process and can achieve unique results. KARL MAYER
is a competent partner for glass weaving mills, with many years ofexperience in the field and offering an exceptionally wide service
network.

ZM-G
Creel

Yarn tensioner

BM

PROWARPFILSIZE S/GFILSIZE F/GAMR-GkARL MAYER WARP PREPARATION

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OUR PROdUCTS
OvERvIEWCREEL

GN-1 – Standard creels
GM – Magazine creels
GD – Swivel-frame creels
GW – Carriage creels
Gv – v-creels
GAR – Unwinding creels
GAM – Unwinding creels monofil
GAPP – Unwinding creels polypropylene

YARN TENSIONER

KFD-2
KFD-B
KFD-AIROPTOSTOP
U2v
U3v
DISCTENS
ISOTENSMEGATENS
MULTITENSACCUTENSE 0°
ACCUTENSE 30°–90°

bEAMING ANd dIRECT
bEAMING MAChINESzM-F – Direct warper for filament yarns
zM-G – Direct warper for glass fiber yarns
WARPDIRECT – Direct warper for spun yarns
BW – Ball Warper
LCB – Long Chain Beamer
BM – Beaming machine

SECTIONAL WARPERS

NOv-O-MATIC – Automatic sectional warper
PROWARP – Sectional warper
ISOWARP – Sectional warper

WARP SAMPLING
MAChINESMULTI-MATIC (MM) – Warp sampling machine

SIZING MAChINESPROSIzE – Sizing machine for spun yarns

GIR-O-MATIC (GOM) – Warp sampling machineISOSIzE – Sizing machine for spun yarns (old SMR-SP)
FILSIzE S/FFILSIzE S/GFILSIzE F/GASSEMbLING MAChINES

AMR-F – Assembling machines

INdIGO dYEING UNITSPRODYE

AMR-G – Assembling machines

ROPEDYE24 / 23

Shirting

Warp Preparation Karl Mayer

Sheeting

Denim

Home textiles

Wool

Silk

Filament

Technical
textilesGlass techGlass elecnical sector tronic sector

KARL MAYER Worldwide© KARL MAYER Textilmaschinenfabrik GmbH
Brühlstraße 25 . 63179 Obertshausen . Germany
www.karlmayer.com
The information provided in this document contains merely general descriptions or characteristics of which may change as a result offurther development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in theterms of contract. Availability and technical specifications are subject to change without notice. All rights reserved.

We-A-1125/1/10/15/4/05/19

Europe Germany Obertshausen, Chemnitz, Frankfurt, Naila Italy Mezzolombardo Switzerland Oberbüren UK Nottingham
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