Karl Mayer: Efficient production of warp knit...
Karl Mayer

Efficient production of warp knitted terry fabric

Karl Mayer

A terry cloth product with double-sided fabric and lively motifs in bright colors has been developed on a warp knitting machine TM 4-TS EL by textile machinery manufacturer Karl Mayer Textilmaschinenfabrik GmbH, Obertshausen/Germany. One side features a dense layer of cotton loops which quickly absorbs moisture from the skin after bathing. The other side consists of sheared polyester (PET). The smooth finish makes it both easier to print on and quicker to dry.

Afterwards the material has been printed at the screen and digital printing machinery manufacturer Zimmer Austria, a business unit of J. Zimmer Maschinenbau GmbH, Kufstein/Austria, using a digital printing process.
Warp knitting technology with a firmly integrated terry loop is very 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 air-jet rapier looms and therefore consumes around 87% less energy/kg 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 US$/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 very 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 air-jet rapier loom.

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