Machines to be Made in India
Sectional warping is one of the crucial processes in warp preparation to produce quality and defect-free warp beams. The ISOWARP sectional warping machine ensures quality warp beams for all types of yarns suitable for shirting, suiting, dress material, upholstery, etc.
KARL MAYER is a pioneer in manufacturing world-class machines for warp preparation. They have been producing many types of sectional warpers, and over the years have supplied these machines across the globe, including hundreds in India. For example, there are close to 150 machines of a single model, the ERGOTEC, running successfully in India! Based on market needs, KARL MAYER had also introduced the ISOWARP model sectional warper, which has been manufactured in Germany and China. Several ISOWARP sectional warpers are also working well in India and Bangladesh.
To meet the growing demand for the ISOWARP model, it has been decided that this model will now also be manufactured in India by KARL MAYER Textile Machinery India Private Ltd., Ahmedabad. Sectional warping is one of the crucial processes in warp preparation to produce quality and defect-free warp beams. The ISOWARP sectional warping machine ensures quality warp beams for all types of yarns suitable for shirting, suiting, dress material, upholstery, etc.
ISOWARP has been proven to run at higher warping and beaming speeds and, in particular, with a substantial simplification of operation, resulting in improved production. Beam-to-beam reproducibility is guaranteed with KARL MAYER’s in-built KAMCOS system, which additionally has easy access to the teleservice network to remotely support machine maintenance. Only warps of the highest quality guarantee optimal efficiency and fault-free fabric in the weaving department. This modern sectional warping guarantees perfect warp quality at maximum productivity, which is a decisive factor for the weaving department.
So how does ISOWARP ensure the best quality warp?
• Optimum warp build-up on the drum with precise positioning of the reed headstock to the cone is achieved fully automatically and with the highest precision. The reed headstock feed movement is followed automatically.
• Uniform cylindrical build-up guaranteed through evener roller ensures that the yarn count variations and yarn volume changes do not cause any density variations.
• The reverse rotation of the drum is important in ensuring a perfect warp sheet laying at its winding point on to the drum with maximum levelling effect from the evener roller.
• The KARL MAYER system permits the optimal winding density while at the same time ensuring minimal yarn loading. Thus, an absolutely cylindrical build-up of the warp is achieved from the first to the last section.
• Thanks to a short distance between the measuring roller and the evener roller, section spread is practically negligible.
ISOWARP is designed to produce production warps for all types of suiting, shirting, sheeting and furnishing applications with the most competitive price-performance ratio.
Unique Features
Its features include:
1. Uniform thread tension.
2. High residual elongation.
3. Exact thread array.
4. No crossed ends.
5. No missing ends.
Several factors are responsible for high productivity. A combination of high speed with minimal yarn tension and optimal operator ergonomic preconditions guarantees maximum productivity. The highest precision with long-term reliability is required to ensure the best warp quality while preparing warp beams on a section warping machine. Also, all ends are wound on to the drum with exactly the same length and uniform tension – this is a key assurance from KARL MAYER.
The ISOWARP further guarantees:
1. Exact cone alignment.
2. Precise section width determination.
3. Extremely precise feed calculation.
4. Evener roller at the running-on point.
5. Automatic section alignment.
6. Automatic section tension control.
Need for Section Tension Control
Through the consistent application of electronic control engineering and the perfect position of an evener roller, modern sectional warping machines can reliably produce a cylindrical material build-up on the warping drum. Equal end length over the whole width of the warp is thus guaranteed. It ensures that the ends are not only wound to be the same diameter, but also with the same thread tension.
Advantages of Section Tension Control
The section tension control measures the overall tension of the warp section immediately in front of the winding-on point on the drum, coverts it into the value for a single end and then compares this figure with the specified figure entered in the system. When any divergence occurs, the CPU adjusts the thread tensioners on the creel until the specified tension range is reached again. Control is so quick and precise that the figure specified is held even in the run-up phase. This means it is possible to achieve fully constant thread tension conditions in every phase of the warping process, independent of:
• Changes in speed, even in the start and stop phase.
• Diminishing package diameter.
• Any warp bobbin change in the middle of the warp.
Indian Scenario
A.T.E. Enterprises Private Ltd. is the sole selling agent for KARL MAYER in India and can guide customers in selecting appropriate technologies and machine configurations to meet their requirements. There are many customer testimonials, as for example, sectional warper ISOWARP from KARL MAYER India delights Rajapalayam Mills. The Rajapalayam Mills Ltd., Rajapalayam, is the textile arm of the Ramco Group and includes spinning mills with a total capacity of about 3,60,000 spindles and about 14,000 OE rotors. They manufacture top-quality compact yarns. Recently they also commissioned yarn-dyed shirting fabric manufacturing operations with 122 looms, weaving preparatory and yarn dyeing system. Ramco uses only high-tech machines to produce high-end products. KARL MAYER is the sole supplier of weaving preparation for their complete weaving production lines.
Rajapalayam Mills installed two ISOWARP sectional warping machines recently and N Mohanarengan, Chief Operating Officer of Rajapalayam Mills was all praise for the excellent performance of ISOWARP. “We are the first one to install the ISOWARP sectional warping machines manufactured by KARL MAYER Textile Machinery India. We have installed two ISOWARP machines with double creels. These machines are working at the highest production level and produce high-quality warp beams, enabling the successful performance of our weaving machines,” he said.
“Since the commissioning of these machines, we are producing the best warp beams for almost all types of yarns, including the finest shirting, with minimum wastage of expensive, high-quality yarn. The machines are maintenance-free and require very few spare parts. The KARL MAYER ISOWARP made in India is real value for money and is on par with the machines made in Germany. We will continue to buy from KARL MAYER India for our future needs. We are proud to have contributed to KARL MAYER’s ‘Make in India’ efforts,” he added. Mohanarengan further said, “We also appreciate that A.T.E. Enterprises and KARL MAYER teams have guided and supported us in selecting the right machine configuration and in the smooth running of our greenfield project.
Similarly, Morarjee Mills is impressed with KARL MAYER technology. Morarjee Mills, Nagpur, focuses on the premium and high-value niche product segments with two divisions: premium yarn dyed shirting and fashion fabric. They produce approximately 25.4 million metres of premium and high-quality fabrics per annum with complete in-house quality yarns. They have a high profile list of clients that includes domestic and international brands across 44 countries. The mills installed many warp preparations machines from KARL MAYER that includes one KARL MAYER ISOWARP sectional warper.
Commenting on the performance of ISOWARP, Subrato Mukherjee, Plant Head, Morarjee Mills, said, “We are very satisfied with the KARL MAYER ISOWARP sectional warper installed in our mills. We have been processing all types of shirting yarns – from medium to superfine cotton yarn varieties – and it produces high-quality beams with almost no defects or wastage of material. We also find that ISOWARP’s maintenance cost is minimal compared to other machines installed in our mills. We are glad to note that we will now get German technology made in India. We are very happy with the excellent support provided by A.T.E. Enterprises and KARL MAYER Textile Machinery India. Both are our suppliers of choice for all our future warp preparation requirements.”