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Report | October 2017

Less water & waste thanks to PRODYE dyeing machines

KARL MAYER ROTAL is making a name for itself with the new PRODYE-R and a huge project in Algeria in the rope dyeing sector.

The denim business is as lucrative as it is varied. Generally, there are three market segments: fashion/premium, genuine/standard and commodity. In the fashion denim business, producers have come to rely primarily on KARL MAYER ROTAL for their warp preparation operations. This Italian subsidiary of KARL MAYER has developed the PRODYE-S indigo dyeing machine to cater for the stylish jeans collections of well-known brand manufacturers, and has thus become a world leader. The ‘S’ stands for slasher dyeing, a dyeing process in which the yarn is wound onto warp beams. On the other hand, there is rope dyeing, which is normally used to produce genuine/standard denim – in which the yarn is dyed in rope form.

The success of PRODYE-S is based on its unique performance. Compared to conventional machines available on the market, this innovative slasher dyeing machine guarantees a much lower water consumption, less waste, and deeper, brilliant indigo shades. The proportion of dyestuff out of the total yarn weight is 5.5 per cent maximum. The production rate can also be doubled when processing lightweight denim fabrics.

KARL MAYER ROTAL’s PRODYE-R indigo dyeing machine can deliver all these benefits and can also be used in the genuine/standard segment.

The PRODYE-R indigo rope dyeing machine operates with just eight dyeing units to produce deep, pure shades with a dye application of up to 5.5 per cent of the yarn weight. The short wet zone reduces the bath volume by up to 25 per cent. Furthermore, when changing the ball, the warp length remaining in the machine, which is unusable, can be reduced by 20 per cent. Overall, the machine uses less energy and water and fewer chemicals. In fact, the water consumption can be reduced by roughly 30 per cent. The programmable cans, into which the dyed ropes are laid in a precise arrangement, also make the long chain beaming process more efficient.

The PRODYE-R complements KARL MAYER ROTAL’s product portfolio. With the new dyeing machine, the BALL WARPER, the LONG CHAIN BEAMER and the PROSIZE, this company is the only global manufacturer involved in the one-stop provision of highly innovative rope dyeing technology. This concept is impressive. One of the biggest companies involved in making-up denim clothing in Turkey, the Taypa Group, is cooperating with KARL MAYER ROTAL on a huge project in Algeria. A textile complex for producing textiles and apparel is to be built on an area of 250 hectares in this North African country, which will create 25,000 new jobs. The planned annual output is 60 million metres of fabric per year.

In December 2013, Taypa set up a joint venture with two state-run Algerian textile companies to implement these ambitious plans. In the first stage of this project in the province of Relizane, eleven integrated factories, mainly for producing jeans and other apparel fabrics, will be set up by the spring of 2018. KARL MAYER ROTAL will supply the warp preparation technology for producing the denim. The first large shipment left for Algeria in the middle of May 2017. 60 containers were needed to ship the PRODYE-R machines alone, of which several were ordered.

A September packed with trade fairs

KARL MAYER participated in Irantex, Techtextil India and Composites Europe. In September 2017, this leading producer of warp knitting and warp preparation machines exhibited on a joint German stand at three trade shows. KARL MAYER started its trade fair marathon by participating in Irantex. The 23rd International Exhibition of Textile Machinery, Raw Materials, Home Textiles, Embroidery Machines and Textile Products took place from September 4-7, 2017 on the site of the Tehran International Permanent Fairground. KARL MAYER displayed a range of samples and information material in the German hall.

There was also a German pavilion at Techtextil, which took place from September 13-15 at Bombay Exhibition Centre. KARL MAYER was one of the many exhibitors on the joint stand, and used the opportunity to show its range of warp knitting and warp preparation machines for producing technical textiles. “In India, as well, conventional textile producers are increasingly looking for another string to their bow and for alternative business fields, and they therefore represent an important target group for our versatile technical solutions,” says the Senior Sales Manager, Bastian Fritsch. The products manufactured on KARL MAYER’s machines are used as blood vessels in the medical sector, as advertising billboards on building façades, as tarpaulins for securing loads on trucks and lorries, and for providing strength and stability when used as geogrids in earthworks. These are just a few of the many applications that are also important in India

Composite Europe demonstrated strong solutions for fibre-reinforced composites KARL MAYER exhibited at Composite Europe with its subsidiary, KARL MAYER Technische Textilien GmbH. This manufacturer exhibited as an indispensable partner to the composites sector at this European trade fair, which took place from September 19-21. KARL MAYER Technische Textilien can supply the COP MAX 4 multiaxial warp knitting machine for producing high-performance composites. This is a flexible, all-round machine for producing multilayered, multiaxial textiles with angles varying from a maximum of +20° to -20°. The COP MAX 5, which is especially suitable for processing carbon fibres, was also be on show. This machine can be used to produce multiaxial textiles in very low weights from carbon fibres. The fibres can be delivered both online or offline. For the offline version, KARL MAYER Technische Textilien can supply the UD 700 fibre spreading unit for spreading the fibre tapes.

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