Satisfactory outcome of the ITMA 2007 for Mayer & Cie. The circular knitting machine manufacturer welcomed almost 7,000 visitors to its stand.

Munich passed its baptism of fire as a trade fair location for the ITMA with flying colours. Visitors to the show numbered a good 118,000, and were quick to confirm their resounding approval of the ITMA 2007 organization both during the set-up phase and throughout the whole of the event.

Almost 7,000 visitors were registered on the Mayer & Cie. trade fair stand over the course of the show. The exhibition met with a lively and highly positive reception, with visitors from Asia, South and Central America particularly heavily represented among the important clients and potential customers visiting the stand.

The exhibits, which were fully abreast of the latest trends and developments in the industry, attracted plenty of attention and approval from visitors. As almost all the innovations on show are available for immediate delivery, reservations flooded in and order books filled quickly.

The ITMA 1999 in Paris had previously held the record as the best ITMA of all time in terms of successful sales. This record has now been busted, with Munich not only exceeding all expectations but also clearly outstripping the achievement of the ITMA Paris in 1999.

Impressive proof was provided among the exhibits on the stand of the aptness of the Mayer slogan “Always in fashion – Quality!”, particularly also in terms of the quality and versatility of the knitted fabrics produced. Flexibility and productivity are currently high up on the list of requirements among knitwear and fabric producers, and here too Mayer & Cie. circular knitting machines set whole new standards. One example of these is relative movement technology, a concept unveiled by Mayer & Cie. for the first time back in 1987 at the ITMA in Paris. With its Relanit machine series, which celebrated its 20-year anniversary in Munich and was represented by the Relanit 3.2 II, Mayer & Cie.’s relative movement technology has long since evolved to become the established current standard in single jersey production.

Exhibits attracting lively attention and continuously surrounded by an interested crowd of onlookers included a gauge E 60 machine electronic individual needle selection in the cylinder and dial cam, and a Relanit knitting top-quality single jersey with elastomer plating at a speed of 45 rpm.

The facility for knitting single and double jersey fabrics on one and the same machine represents a whole new departure in the knitting machine sector. This machine, also a highly popular exhibit, is planned to be released for delivery in the middle of 2008.

Also right up abreast of the latest developments in the industry and highly successful at the show was the BasicLine machine series. Model upgrades in both the double and single jersey segment were exhibited.

20 years of Relanit! Whether cotton or synthetics – Relanit 3.2 II comes up trumps every time.

The Relanit 3.2 II is ideally suited for working with the latest synthetic yarns. Alongside the benefits of relative movement technology, the use of special machine settings allows the Relanit 3.2 II to achieve its full machine output irrespective of whether it is processing cotton or synthetic yarns.

An interesting new feature is a High Speed Kit (option), which permits the manufacture of single jersey with full elastomer plating at a continuous speed of up to 45 rpm with a 30” diameter. Which adds up to 1.8 m/s for full elastomer plating – a previously unattainable performance.

The technical background: While the Relanit 3.2 II works as standard with yarn guides in offset position, for fashion synthetic yarns and elastomer a yarn guide can be placed in front of the needle curve. In conjunction with a special needle hook, this allows the positioning of both yarns to be optimized so as to ensure that the full knitting output is available at all times.

Another new feature: The patented MCS (Mayer Cleaning System) offered as an optional extra for the Relanit 3.2 II. This device provides convincing proof that practically oriented engineering always produces the best results. With MCS, Mayer & Cie. has created not only an effective cleaning function, but also an additional cooling system for the knitting head. The MCS guides ambient air under pressure through a channel into the segments and selectively directs it upwards. This largely prevents the penetration of lint into the entire stitch-forming area, and removes dirt from the cam and needle areas, not only substantially increasing the service life of needles and sinkers as a result of reduced wear, but also optimizing fabric quality and increasing cleaning intervals.

Relanit 3.2 II – Facts and figures:

Single, jersey, 4-needle structures and single plated.

Cylinder diameter 26“ – 38“

Machine gauges E 18 – E 32

Number of feeders 3.2 inches (96 feeders with 30“)

Speeds up to 1.8 m/s. (45 rpm with 30“)

Gauge E 60 – knitted silk effect with the MV 4-3.2 II circular knitting machine

Its versatility and high output have made this single jersey machine a top sales hit over many years. Mayer & Cie. has now raised the standard still higher, extending the knitting gauge range to an enormous E12 to E 60! The machine is equipped with all the right qualities to turn increased output, quality and reliability into higher profitability and optimum sales scope for the produced fabrics. The sinker shape, double guidance of the sinker and sinker cam are specifically developed for the MV 4-3.2 II, so guaranteeing an even fabric appearance and at the same time reducing sinker wear.

From gauge E 36, the new CONI++ feeder is used. This ensures optimum division of threads on ceramic pins and reliable thread guidance to the needle. Additional sinker cam carriers ensure absolutely stable supporting, while a new temperature control system guarantees the optimum operating temperature at all times. All of which adds up to a defined fabric quality – from the first to the last stitch.

The MV 4-3.2 II provides the perfect solution for producing a wide range of single jersey fabrics. In the Fine Touch sector it opens up whole new markets, as high-quality yarns in cotton, viscose, polyester are used to create top-class fabrics for quality underwear, shirts, blouses and other high value outerwear products. The fabrics have a fine, expensive feel with the quality of silk, while at the same time offering pleasant elastic properties and optimum wearing comfort.

MV 4-3.2 II – Facts and figures:

Single jersey, 2 and 4-needle structures, crepe, two-thread fleece and single jersey plated.

Cylinder diameter 10“ – 36“, 42“, 48“

Machine gauges E12–E32, E36, E38, E44, E50, E54, E 60

Number of feeders 3.2/inches (96 feeders with 30“)

Speeds up to 1.3 m/s. (33 rpm with 30“)

The whole range of popular structures in double and single jersey: FSI 3-2.0 QC.

This is a uniquely flexible, and consequently highly profitable option. Just one versatile machine is able to knit both rib and single jersey – with up to three needle tracks in the cylinder cam and two needle tracks in the dial cam. Not only automatic knitting-on after a thread breakage but also the high quality of its rib fabrics are features adopted from the successful FS 2.0. In the event of a machine standstill, stitches remain in position supported by the sinker, and knit on again automatically with absolute reliability. Laborious and time-consuming joining on is a thing of the past.

In the field of rib fabrics, this machine covers the entire underwear range from plain rib to tuck rib. It produces top quality fabric with high elasticity by plating on dial needles, both for normal plating and when using elastomers.

In the single jersey sector, the FSI 3-2.0 QC knits structures such as fleece, pique and much more with 3 needle tracks.

Knitters are afforded even greater flexibility with the Mayer & Cie. gauge change system Quick-Change, which allows quick and simple gauge changeovers.

FSI 3-2.0 QC – Facts and figures:

Rib fabrics from plain rib to tuck rib including plated knits.

Single 3-needle structures such as fleece, piqué constructions and many more.

Cylinder diameter 14“ – 26“, 30“, 34“

Machine gauges Rib E 12 – E 20

Single jersey E 12 – E 28

Number of feeders 2.0/inches (62 fds. with 30“)

Speeds up to 1.5 m/s. (38 rpm with 30“)

A unique success story takes on a new dimension: The OVJA 1.6 E is now joined by the OVJA 1.6 EE.

For the knitting sector, the name OVJA 1.6 E links outstanding productivity with the benefits of universal application. With the OVJA 1.6 EE, knitters are now offered electronic individual needle selection not only in the cylinder cam but in the dial cam too, opening up whole new production possibilities for patterning and structures as the dial needles also perform a patterning function – with electronic control. At the same time, electronic pattern changeover ensures minimal resetting times, making even small production runs a profitable proposition. Pattern processing takes place with the aid of MDS 1, Mayer & Cie.’s own internally developed design software.

Full MCT electronics, based on individual needle selection with just one magnet per feeder, has been internationally patented by Mayer & Cie. It is considered throughout the industry as exemplary and has since proven successful in practical application in thousands of machines the world over.

With this outstanding electronic individual needle selection system, the new OVJA 1.6 EE is ideally equipped to produce top-quality jacquard qualities to fulfil current fashion demands as well as for modern mattress fabrics – with outstanding ease and reliability.

OVJA 1.6 EE – Facts and figures:.

Full jacquard designs and structures on both fabric faces with full electronic control.

Cylinder diameter 30“ – 38“

Machine gauges E 18 – E 28

Number of feeders 1.6 inches (48 feeders with 30“)

Speeds up to 0.8 m/s. (20 rpm with 30“)

Full 3-way jacquard, with full electronic control on both fabric faces, featuring stripes, transfer and welt. On just one machine: The OVJA 1.1 TTRB.

Whatever the world of fashion demands, this machine is capable of making (practically) any requirement a reality. Because 3-way jacquard plus automatic stitch length adjustment for the welt add up to outstanding patterning variety for both fabric faces. Electronic 3-way individual selection of the cylinder and rib needles ensures the fast transfer of any pattern to the machine, while stripes and transfer add another dimension to the patterning variety – even for fully fashioned parts. In this case, the OVJA 1.1 TTRB knits with separating thread and welt. The facility for elastomer plating in defined areas is perfect for affording sufficient elasticity for parts such as waistbands.

Automatic stitch length adjustment simplifies operation and helps avoid setting errors. It takes place electrically by means of pattern control and can consequently be reproduced at any time.

Tried and tested Mayer & Cie. fully electronic control guarantees minimal resetting times. The cylinder cam can be simply reset, and needle selection in accordance with the new pattern starts immediately. The dial cam also operates using electronic individual needle selection.

The OVJA 1.1 TTRB offers unique patterning variety coupled with extremely simple resetting of the fabric reverse, making even small batch sizes viable.

OVJA1.1 TTRB – Facts and figures:.

Double jersey jacquard and structures for both fabric sides, fully electronic control, with stripes, transfer and welt.

Cylinder diameter 34“

Machine gauges E 14, E 16, E 18

Number of feeders 36

Speeds up to 0.8 m/s. (18 rpm with 34“)

BASICLine – an independent machine series.

Although the intention behind this machine series was never in doubt, the scale of its success was still astounding. BASICLine has opened up the possibility of aspiring to Mayer & Cie. quality to a far broader spectrum of circular knitting producers. The price benefit is achieved through widespread standardization in production, and a broad-based equipment range is making this series an interesting proposition for a growing number of circular knitting factories.

BASICLine double jersey: D4-3.2 offers even more output with higher number of feeders.

The BASICLine double jersey machine series featuring the D4-2.2 for interlock and all popular jersey structures has now been increased to include the D4-3.2.

As standard, this machine is supplied with 2 needle types and 2 needle tracks in the dial and cylinder cam, but in design terms it is configured for 4 needle tracks in the cylinder cam.

The D4-3.2 knits all popular double jersey structures and interlock, for instance Double Face, Punto di Roma, Milano Rib with the high output of 3.2 feeders per inch and a speed of up to 1.4 m/s.

As with all the models of the BASICLine series, the D4-3.2 is also equipped as standard with low-wear ceramic yarn feeders.

For fast gauge changes, a new Quick Change version is available in which the dial cam can be centred into position from above. This simplifies the gauge change process and results in substantially shorter resetting times.

D4-3.2 – Facts and figures:.

Interlock and all currently popular double jersey structures.

Cylinder diameter 30“ – 38“

Machine gauges E 18 – E 32

Number of feeders 3.2/inches (96 feeders with 30“)

Speeds up to 1.4 m/s. (35 rpm with 30“)

BASICLine single jersey – the right machine every time,

To date, the BASICLine range Single has been based on the S4-3.2 for single jersey, 2 to 4 needle structures and single jersey plated. At the ITMA, Mayer & Cie. exhibited two additional variants: The SF4-3.2 for three-thread fleece and four-needle structures as well as the S4-3.2 R for fashion stripes.

Based on a modular structured system over the entire machine series, every one of the BASICLine single jersey machines can each be converted to a different version. The S4-3.2 R can be converted for instance from the striping version to the basic version S4-3.2. Depending on the order situation, this allows either fashion stripes to be produced, or a basic fabric at a high output of 3.2 feeders per inch.

SF4-3.2 – everything for light or heavyweight three thread fleece and 4-needle structures.

Like all BASICLine machines, the SF4-3.2 is distinguished by highly productive, low-cost production coupled with optimum knitting quality. The wide fabric weight adjustment range is simply and precisely implemented by means of central height adjustment, while fine adjustment takes place by vertical stitch forming. A special lay-in technique for the fleece thread makes the SF4-3.2 a reliable specialist in the manufacture of elastic light-weight fleece fabrics.

Its outstanding flexibility is extended still further by its facility for simple conversion to model S4-3.2 for single jersey and structures. For this purpose, Mayer & Cie. offers a low-cost conversion kit.

Needles and sinkers are internationally easily available standard knitting elements which can be replaced at affordable cost. The portal frame with its capacity for 480 mm fabric rolls (wrapping winder mechanism) comes as standard. The range also includes an optional folding device.

To prevent permanent creasing, particularly with sensitive yarns, Mayer & Cie. offers an open-width device for 280 mm fabric rolls.

SF4-3.2 – Facts and figures:.

Three-thread fleece and single jersey in 2 or 4-needle structures.

Cylinder diameter 30“ – 36“

Machine gauges E 18 – E 24

Number of feeders 3.2/inches (96 feeders with 30“)

Speeds up to 1.4 m/s. (35 rpm with 30“)

Fashion stripes or high-volume single jersey production: S4-3.2R.

The S4-3.2R knits fashion stripes with up to 6 colours over 1.6 feeders per inch, making use of the same proven Mayer & Cie. striping technology used in thousands of machines the world over. The ingeniously simple mechanical functional sequence operates with absolute reliability and requires only minimal maintenance.

The high degree of flexibility achieved by this striping machine is the result of its scope for replacing striping miss-knit feeders by knitting feeders. Following this simple conversion, a high-performance single jersey machine with 3.2 feeders per inch is available for single jersey in 2 to 4-needle structures as well as single jersey plated.

A Quick-Change gauge conversion takes place with the utmost simplicity and time savings, without the need to remove striping attachments in the striping version.

S4-3.2R – Facts and figures:

Single jersey striped fabrics and single jersey in 2 and 4-needle structures

Cylinder diameter 30“ – 34“

Machine gauges E 18 – E 32, E 36

Number of feeders 1.6/3.2/inches (48/96 feeders with 30“)

Speeds up to 0.9 / 1.4 m/s (22 / 35 rpm with 30“)

Open-width device with BASICLine.

For the BASICLine machine series, Mayer & Cie. offers two open-width variants. A new feature is the open-width frame “made in Germany” – a Mayer & Cie. development specifically for BASICLine machines. The fabric width can be individually adjusted by means of a scale, so ensuring that each order can be precisely reproduced at any time.

The “made in Asia” open-width version has proven successful in practical operation time and time again and has also been used in BASICLine machines for several months already. This simpler version is not fitted with a scaling facility.

Both open-width frames can be converted for tube winding.

Transparency in the circular knitting machine: MDA.web.

The three letters “MDA” stand for the term “Machine Data Acquisition”. Mayer & Cie. has further developed the MDA concept to create the global system MDA.web, which can be operated both via the company’s own Intranet and also on a worldwide basis via the Internet.

In a manner of speaking, the MDA.web permits the complete circular knitting factory to be transferred to the screen, where all the important production and performance data can be accessed. Internal procedures such as order processing and capacity planning through to yarn management can be effectively optimized. A more efficient system of production monitoring makes delivery dates more reliable, allows set-up and throughput times to be reduced, and productive machine running times to be increased.

As the system is based on internationally used standards, it can easily be interlinked using Ethernet PC networking technology. The existing network structure can be used, so significantly reducing investment costs.

The use of the internet allows both producing facilities in different locations and also the user’s own central production base to be accessed and monitored remotely while the user is out of the office.

MDA.web is a significant and useful management instrument providing valuable basic data for entrepreneurial decisions.