Karl Mayer: System for automatic batch change
Karl Mayer

System for automatic batch change

The fully automatic knotting unit on the Link-Matic system (Source: Karl Mayer)
The fully automatic knotting unit on the Link-Matic system (Source: Karl Mayer)

A sophisticated automation solution that considerably simplifies the batch change on indigo and sizing machines has been launched by Karl Mayer. With the Link-Matic system an increase in productivity of up to 30% is possible, depending on the number of batch changes per day.
In addition, less yarn waste is produced. Up to 600 m, on indigo dyeing range, of unusable yarn material can be saved with each batch – while at the same time requiring less manpower. During batch changes, only one operator is required to prepare the warper beams for entry into the machine. A fully automatic knotting unit couples the warp yarns of the new batch to the yarns of the batch just finished.
Link-Matic makes it possible to automate the batch change on the Prodye-S and Prosize with 2 subsystems. The first subsystem focuses on feeding the yarn sheets of the new batch from the warper beams to the infeed of the machine. The yarn material is guided to its destination in the lower section of the warper beam frame. Previously, it had to be threaded by hand by 2 people. With the new solution, only one operator fixes the warp yarns. The yarns are guided to the machine with uniform, constant tension. Here, the second dividing system cuts the warp yarns of the finished batch at the infeed and knots on the warp yarns of the new batch - each with high precision and fully automatically. The actual batch change can thus be reduced to 90 seconds. The new Link-Matic system can develop its full potential in conjunction with a moveable creel.
Denim manufacturer Lotustex Textile Co., 10th of Ramadan City/Egypt, has invested in the innovative Link-Matic system in recent months in order to optimize the performance of its Prodye-S sizing machine. Especially for its activities in the fashion sector, Lotustex expects a significantly higher flexibility and cost reduction. The delivery date for the new acquisition is November 2022.

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