Soft sportswear fabric produced on the RSJ 4/1 ON, with climate-controlling effect, thanks to the breathable mesh design and the processing of Meryl Cool EcoDye yarn with a cooling effect on the inside. © Karl Mayer

The new Karl Mayer’s RSJ 4/1 ON raschel machine exploits all the advantages of integrated software solutions and electronic guide bar control when producing patterns. This new machine reduces the time-to-market and brings a touch of individuality to the mass market, the leading German manufacturer reports.

It makes use of the high-tech connectivity of the k.ey and k.innovation systems in Karl Mayer’s KM.ON digital brand. The RSJ 4/1 ON is the first machine to integrate the extensive k.innovation systems to optimise the virtual development of textiles. Thanks to its collaborative features, k.innovation is designed to deliver more than just patterning software and focuses on a new type of product development.

Digitisation and innovative machines

“Digitisation and innovative machines go hand in hand,” the company says. “A process without system breaks ensures that the results of virtual textile development are transferred directly to the machine via the secure KM.ON cloud. This enables prototypes to be produced quickly and reliably when developing new products, and long repeats with lapping changes can be produced.”

Thanks to the EL technology as standard, articles can be changed quickly during production practice, and this increases flexibility. The RSJ 4/1 ON is also designed to deliver maximum productivity. With a 50% wider working width, this new machine is said to offer a 37% better cost:benefit ratio than its predecessor for the same speed.

Fabric produced on the RSJ 4/1 ON with two-colour effects produced by specifically using different yarns in the ground and jacquard bars and with a cooling effect produced by processing functional Meryl Cool EcoDye on the inner and outer sides. © Karl Mayer

Like other state-of-the-art products produced by the Karl Mayer Group, the machine can be networked to other intelligent KM.ON systems via k.ey to increase production efficiency. The machine is available with a working width of 195" and a gauge of E 28. The first machines will be available at the beginning of 2020.

Design freedom

In today’s fast-changing world, innovation cycles are becoming shorter and shorter, and exchanging know-how and expertise in the search for something new is becoming more and more important – and this also applies to the warp knitting sector.

The k.innovation systems include a web-based design tool, so that customers can produce the jacquard patterns themselves or else modify them according to their own ideas. Global collaboration with creative internal and external partners is, therefore, efficient and secure.

The knitting elements on the RSJ 4/1 ON. © Karl Mayer

The RSJ 4/1 ON also scores points in terms of its design possibilities. Electronically controlled guide bars enable products with variable ground structures and long lapping repeats to be produced, and this technical advantage, together with the excellent cost:benefit ratio, makes innovative textile applications attractive in wide segments of the market.

Easy way to produce semi-finished fabrics

The RSJ 4/1 ON brings its advantages to bear when patterning, especially when producing textiles with complex designs, functional zones and style-relevant contours. The semi-finished fabrics reduce costs and improve wear comfort. They reduce the number of separate pieces needed to create a garment. Processing times for making changes at the development stage can be reduced because fewer design elements are needed. Reducing the number of seams in the finished product increases the wear comfort considerably, whilst reducing making-up costs at the same time. Patterns with integrated structural variations, together with the possibilities offered by the RSJ 4/1 ON, enable fashion trends to be catered for quickly.

Innovation through digital integration

In addition to the greater ease and flexibility when patterning using k.innovation, the RSJ 4/1 ON also offers advantages by integrating the latest developments from the KM.ON product groups, k.production and k.management. The modern software and digital systems of k.production are designed to simplify the operations of the production machine.

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