v

WA R P P R E PA R AT I ON

COMPLETE SOLUTIONS
FOR YOUR SUCCESS
IN WEAVING

Shirting / Sheeting / Denim / Home Textiles / Wool

/ Silk / Filament / Technical Textiles / Glass
KARL MAYER WARP PREPARATION

WARP PREPARATION
COMPLETE PROCESS
SOLUTIONS
 WARP PREPARATION KARL MAYER

ZERO DEFECT AND 100 %

CAPACITY UTILIZATION
One of our main objectives is to ensure that your weaving mill produces at the
highest efficiency. We are the only manufacturer in the world who offers
complete process solutions for the warp preparation business. Therefore we
offer you the highest reliability for economic efficiency, quality and flexibility
of your weaving factory.

Since 1991 we, as market leader, have been providing our customers with
sustainable concepts. Innovative technology and reliable service structures
guarantee the durability of your machines. KARL MAYER has agencies all
over the world, at our customers‘ locations. Our global service network
provides you with quick and targeted service solutions. Pre- and aftersales
concepts support the long service life of your equipment and processes.

Our integrated processes ensure zero defect and 100 % capacity utilization
for your machines during production. Our Centers of Excellence develop
special solutions for your complete business activities. We can also offer
you tailor-made development solutions for your special requirements.

With our ground-breaking innovations we are always one step ahead. This
competitive edge is the result of our professional development management
and of our excellent relations to textile and technical colleges and universi-
ties. Our technology leadership also becomes evident by numerous applica-
tions of innovative patents.

This leaflet shows you our entire product portfolio and the appropriate
technical solutions. Please kindly contact us if you have questions regarding
your individual issues and wishes. Our experts are looking forward to meeting
you and having a personal conversation with you. They would be pleased to
hand you over detailed technical folders for your specific requirements.

We are looking forward to hear from you!

KARL MAYER WARP PREPARATION

04
05

10 03
06 08

01

09

12 07
 WARP PREPARATION KARL MAYER

11
02 CONTENT
01 INNOVATIONS 6 – 7

02 COMPLETE SOLUTIONS 8 – 11

03 SHIRTING 12

04 SHEETING 13

05 DENIM 14

06 HOME TEXTILES 15

07 WOOL 16

08 SILK 17
13
09 FILAMENT 18

10 TECHNICAL TEXTILES 19

11 GLASS – TECHNICAL SECTOR 20

12 GLASS – ELECTRONIC SECTOR 21

13 PRODUCT OVERVIEW 22
KARL MAYER WARP PREPARATION 06 / 24  

INNOVATIONS
ALWAYS ONE STEP AHEAD

LATEST WARPING TECHNOLOGY IN PATTERN YARN SELECTOR MADE

COMBINATION WITH KAMCOS® 2 FROM CARBON AND PATENTED
ensure highest quality level through self-optimizing CENTER-YARN TRANSPORT FACILITY
layer regulation
guarantee most precise yarn laying at highest speed

EXTENDED APPLICATION RANGES NEW INTERMINGLING

WHEN USING DYNAMIC YARN TECHNOLOGY NOZZLES
TENSIONERS More intermingling points but less energy consumption
and considerably easier handling
result in more flexible applications even when
operating at lowest yarn tensions
24 / 07 WARP PREPARATION KARL MAYER

EXTENSION OF WARP SAMPLING FLEXIBILITY DUE TO CONSISTENT

APPLICATIONS FURTHER DEVELOPMENT
NEW YARN CONVEYING BELTS A newly developed equalizing roller, now also available on
fully automatic machines, gives you a competitive edge
Pneumatically controlled yarn conveying belts
ensure a constant yarn tension in all warping bands

MOST EFFICIENT SIZING BEST DENIM QUALITY THANKS TO

TECHNOLOGY WITH PROSIZE® THE DOUBLE VARIO TECHNOLOGY
Innovative, immersion-free sizing process. Easy handling and The Double Vario technolgy with two dyebaths
unrestricted view of the entire processing sequence due to ensures high, uniform dyeing and deep indigo shades
vertical yarn guiding
KARL MAYER WARP PREPARATION 08 / 24  

PROCESS OVERVIEW

Bobbins

Creels

Our integrated processes ensure zero defect

and 100 % capacity utilization for your machines
during production.
Direct
Warping

Sectional Warping

Sample Warping

Ball Warping
 Denim Slasher
Dyeing

Long Chain
Beaming

Denim Rope
Dyeing
 WARP PREPARATION KARL MAYER

Assembling

Sizing

Weaving Beam
KARL MAYER WARP PREPARATION 12 / 24  

YOUR BENEFIT
First-class quality
• Shirting made of dyed or raw yarns of
SHIRTING outstanding quality
• Plain or striped textiles
TAILOR-MADE ORDER HANDLING • Reproducible results in terms of density
and colour
Only a made-to-measure shirt has a perfect fit. And only a made-to-
• Minimum yarn breakage rates during all
measure order handling in warp preparation for weaving guarantees
process stages
maximum quality as well as cost-efficient solutions. Regardless of
• Unsurpassed gentle yarn treatment for
whether you want to process raw or dyed yarns, in batches of short
first-class results
or long lengths, whether you want to produce plain or striped fabrics
• Gives your designers a vast scope to
– with KARL MAYER’s flexible machines you can always be sure to
express their creativity
manufacture first-class warp beams in a most efficient and favourab-
ly-priced way.
Process know-how
• Specialized system expertise and complete
product portfolio
• Improved machines for batches of short and
long meters
• Electronic control system for highest process
GIR-O-MATIC
reliability
• Flexible technology for all requirements
MULTI-MATIC • Cross-process quality management

Creel Yarn tensioner NOV-O-MATIC Profitability

ISOSIZE
PROSIZE • Specialized system expertise and complete-
PROWARP product portfolio
• Improved machines for batches of short and
ISOWARP long meters
• Electronic control system for highest process
WARPDIRECT
reliability
• Flexible technology for all requirements
• Cross-process quality management
24 / 13 WARP PREPARATION KARL MAYER

YOUR BENEFIT
First-class quality
• 100 % reproducible quality due to automatic
process control SHEETING
• Minimum yarn breakage rates during all
process stages
MORE COMPETITIVENESS
• Unsurpassed gentle yarn treatment for
In times of decreasing profit margins and ever increasing competition
first-class results
you can take advantage of state-of-the-art machines offering highest
efficiency, thus, being the decisive basis for more competitiveness.
Process know-how
Successful weaving mills rely on KARL MAYER’s machines. No matter
• System expertise and complete product
which raw materials are used and which specific products and qualities
portfolio
are to be achieved, KARL MAYER’s warp preparation machines ensure
• Improved machines for warp beams with
reliable production cycles, consistent quality and the decisive increase
15,000 and 30,000 yarn ends
in productivity.
• Electronic control system for highest
process reliability
• Flexible technology for all requirements
• Cross-process quality management

Profitability
• Permanently high productivity in warp
preparation for weaving
• Minimum yarn breakage rates GIR-O-MATIC

• High efficiency
• More process reliability and higher MULTI-MATIC
productivity in weaving
• Production-supporting services such as Creel Yarn tensioner NOV-O-MATIC
ISOSIZE
remote maintenance of the machines PROSIZE
ISOWARP

WARPDIRECT
KARL MAYER WARP PREPARATION 14 / 24  

YOUR BENEFIT
First-class quality
• Extremely wide range of colours and unique
DENIM look of your denim products
• 100 % reproducible quality due to automatic
PRODYE - THE KEY TO SUCCESS process control
• Uniform yarn guiding for ensuring the best
Denim as an “evergreen” product in the clothing sector has increasingly
dyeing and sizing results
developed to a sophisticated fashion article with personal touch and
• Keeping the original yarn properties
rapidly changing trends. Therefore, flexibility is the number one suc-
• Higher intrinsic value of your products for
cess factor for weaving mills. With its PRODYE KARL MAYER offers
higher profit margins
you the entire denim process technology for weaving warp preparation
from a single source. It doesn’t matter whether you decide on the
Process know-how
slash-dyeing procedure or on the rope-dyeing method, KARL MAYER’s
• Outstanding flexibility
PRODYE is always the most productive and economical solution.
• Additional components for special effects in
the dyeing process
• Intelligent control system for optimum
tension control and gentle-to-yarn sizing
• High-grade yarn tensioners for uniform,
lowest yarn tension
• High ease of operation
• Maximum protection against soiling

Profitability
• 20 % more productivity in slash-dyeing
• Low wastewater pollution
BW • Highest efficiency due to reduced yarn
breakages and optimum yarn quality
Creel Yarn tensioner LCB • Cleaning during machine operation ensues
PRODYE
more productivity
PROSIZE
WARPDIRECT
24 / 15 WARP PREPARATION KARL MAYER

YOUR BENEFIT
First-class quality
• 100 % reproducible quality due to automatic
process control HOME TEXTILES
• Best results thanks to uniform yarn tension
• Minimum yarn breakage rates in all process
COMPETITIVE EDGE THANKS TO EXPERTISE
stages
Gain the lead and make use of KARL MAYER’s expertise to achieve a
faster and more economical production with highly efficient machines.
Process know-how
Based on reliable profitability calculations KARL MAYER’s experts are
• Specialized system expertise and complete
able to offer you the ideal solution for your weaving warp preparation
product portfolio
business. Become more competitive by means of special solutions.
• Customized, optimized machines
Machines of double width ensure, for example, an efficient patterning
• Production of wider warp beams of up
for upholstery fabrics.
to 3.60 m
• Electronic control system for highest process
reliability
• Flexible technology for all requirements
• Cross-process quality management
GIR-O-MATIC

Profitability
MULTI-MATIC
• Profitability calculations offered by our team
of experts
• More efficient processes due to highest NOV-O-MATIC

productivity in the long term

Creel Yarn tensioner FILSIZE S/F
• Reduction of manufacturing costs ISOWARP
AMR-F
• Production-supporting services such as ISOSIZE
remote maintenance of the machines PROWARP PROSIZE

WARPDIRECT

ZM-F
KARL MAYER WARP PREPARATION 16 / 24  

YOUR BENEFIT
First-class quality
• 100 % reproducible quality due to automatic
WOOL process control
• Maximum accuracy for high efficiency
EXCITING BY QUALITY • Gentle yarn treatment due to uniform yarn
tension
Experienced wool weaving mills know how to impress and delight
• Constant, completely homogeneous dyeing
sophisticated fashion labels: with exclusive quality at competitive
results
prices. Perfect warp preparation with KARL MAYER’s innovative
technology is the key to success. It preserves the original properties
Process know-how
of the delicate wool yarns and blended wool yarns, so that a faultless
• Specialized system expertise and complete
and productive operation is possible in weaving.
product portfolio
• Improved machines for efficient warp lengths
• Automatic warping with GIR-O-MATIC® and
MULTI-MATIC®, maximum precision due to
special warping bands
• Electronic control system for highest process
reliability
• Flexible technology for all requirements
• Cross-process quality management

GIR-O-MATIC Profitability
• Less material usage, reduced waste
MULTI-MATIC • Production-supporting services such as
remote maintenance of the machines
Creel Yarn tensioner NOV-O-MATIC
ISOSIZE
PROSIZE
ISOWARP

PROWARP
24 / 17 WARP PREPARATION KARL MAYER

YOUR BENEFIT
First-class quality
• 100 % reproducible quality even in case of an
unsteady nature of the raw material, due to SILK
automatic process control
• Gentle yarn treatment and protection of the
SPECIAL TREATMENT FOR A SPECIAL YARN
original yarn properties
The prima donna amongst yarns is extremely demanding, and wants
• Uniform yarn guiding for obtaining best
to be given a special treat during its processing from the bobbin to the
dyeing and sizing results
loom. This is the reason why KARL MAYER developed the ISOTENS®
• Highest quality standard with “zero defect
and MULTITENS® yarn tensioners, a technology that guarantees a
tolerance”
uniform yarn tension during the entire process of warp preparation for
weaving, at the same time compensating for an unsteady condition of
Process know-how
the raw material. When it comes to silk there’s no room for compromi-
• Specialized system expertise and complete
ses. Therefore, rely on KARL MAYER’s machines.
product portfolio
• Improved machines with maximum flexibility
• Uniform yarn tension by means of ISOTENS
and MULTITENS
• Electronic control system for highest process
reliability
• Cross-process quality management

Profitability GIR-O-MATIC

• Highest efficiency and maximum productivity

• First-class process reliability in weaving MULTI-MATIC
• Reduced material usage and less waste
• Lower stock reserves due to just-in-time Creel Yarn tensioner NOV-O-MATIC
production
• Production-supporting services such as ISOWARP
remote maintenance of the machines.
PROWARP
KARL MAYER WARP PREPARATION 18 / 24  

YOUR BENEFIT
First-class quality
• Perfect conservation of the original residual
FILAMENT elongation of the yarn and of its other
properties: from the first to the last meter
ANYTHING IS POSSIBLE • Absolutely homogeneous dyeing results due
to uniform yarn tension during direct beaming
The applications of filament yarns are almost unlimited. Lightweight,
• Highest process reliability in weaving due to
airy fashion fabrics, trendy functional garments, classical linings or
uniform yarn tension and optimum sizing
technical textiles with particular properties – anything is possible.
Therefore, high demands are made on warp preparation for weaving.
Process know-how
For the special physical properties of filaments KARL MAYER can offer
• System expertise for all applications: from
the most suitable process technology. Take advantage of the most
the finest monofilament yarns for filter
flexible, most efficient and cost-saving solutions worldwide!
fabrics up to high-tenacity multifilaments for
tire cord
• Yarn guidings and yarn tensioners made from
special wear-resistant ceramics
• Roller feeding devices for tension control in
case of special applications
• Worldwide unique regulating systems in
GIR-O-MATIC
sectional warping, intermingling and sizing
for continuous quality assurance
MULTI-MATIC

Profitability
Creel Yarn tensioner NOV-O-MATIC • Achieving high potential savings in all process
FILSIZE S/F
AMR-F stages
PROWARP • Highest efficiency due to yarn breakages
reduced to minimum
BM • Competitive advantages thanks to reproduci-
ble best yarn quality
ZM-F
• Low current costs
24 / 19 WARP PREPARATION KARL MAYER

YOUR BENEFIT
First-class quality
• Documented processes
• 100 % reproducible quality due to automatic TECHNICAL TEXTILES
process control
• Computer-controlled quality management
PROVEN, DOCUMENTED QUALITY
for the entire process
Very often technical textiles make great demands on the quality
• Wide range of materials to be used
management. Therefore, 100 % reproducible processes are a „must“ in
warp preparation for weaving. In this respect, a highly specialized
Process know-how
know-how is required because the processing widths and tensile forces
• Specialized system expertise and complete
exceed the usual dimensions many times over. But by using KARL
product portfolio
MAYER’s machines you will be able to master these challenges without
• Improved machines for especially wide warp
any problems.
beams (up to 5.40 m) and high warp tensile
forces
• Electronic control system for highest process
reliability
• Flexible technology for all requirements
• Cross-process, documented quality manage-
ment for all processes

Profitability
• Highest productivity in all applications
• High efficiency
• Reduced material usage, less waste ZM-F
• Efficient, flexible processes with low
personnel expenses Creel Yarn tensioner ZM-G PROSIZE
• Production-supporting services such as FILSIZE S/F
AMR-F
remote maintenance of the machines BM

PROWARP
KARL MAYER WARP PREPARATION 20 / 24  

YOUR BENEFIT
First-class quality
• 100% reproducible quality due to automatic
GLASS – TECHNICAL SECTOR process control
• Computer-aided quality management during
HIGHLY SPECIALIZED COMPLETE SOLUTIONS the entire process
• Homogeneous degree of sizing
Consistent high quality, maximum process reliability and 100 % repro-
• Precise winding structure
ducibility – KARL MAYER offers highly specialized complete solutions
for glass processing for weaving warp preparation in case of which all
Process know-how
the components are perfectly synchronized. In this way, you can cont-
• Specialized system expertise and complete
rol the complete process and can achieve unique results. KARL MAYER
product portfolio
is a competent partner for glass weaving mills, with many years of
• Improved, innovative overall solutions for
experience in the field and offering an exceptionally wide service
highest efficiency
network.
• Camp-cross control of all production
processes
• Electronic control system for highest process
reliability due to KAMCOS®
• Perfect yarn tension and circumferential
control
• Cross-process quality management
• Compensator-controlled assembling
machines for the processing of very fine
glass fiber yarns

Profitability
ZM-G • Maximum productivity and highest efficiency
• Minimum yarn breakage rates
Creel Yarn tensioner BM • Efficient and flexible processes for all yarn
FILSIZE S/G
counts
AMR-G
PROWARP
• Production-supporting services such as
remote maintenance of the machines
24 / 21 WARP PREPARATION KARL MAYER

YOUR BENEFIT
First-class quality
• 100 % reproducible quality due to automatic
process control GLASS – ELECTRONIC SECTOR
• Computer-aided quality management during
the entire process
HIGHLY SPECIALIZED COMPLETE SOLUTIONS
• Homogeneous degree of sizing
Consistent high quality, maximum process reliability and 100 % repro-
• Precise winding structure
ducibility – KARL MAYER offers highly specialized complete solutions
for glass processing for weaving warp preparation in case of which all
Process know-how
the components are perfectly synchronized. In this way, you can cont-
• Specialized system expertise and complete
rol the complete process and can achieve unique results. KARL MAYER
product portfolio
is a competent partner for glass weaving mills, with many years of
• Improved, innovative overall solutions for
experience in the field and offering an exceptionally wide service
highest efficiency
network.
• Electronic control system for highest process
reliability due to KAMCOS®
• Perfect yarn tension and circumferential
control
• Cross-process quality management
• Compensator-controlled assembling
machines for the processing of very fine
glass fiber yarns
• ACCUTENSE 0° for the gentle deflection of
sensitive glass filament yarns

Profitability
• Maximum productivity und highest efficiency ZM-G
• Minimum yarn breakage rates
• Efficient and flexible processes for all yarn Creel Yarn tensioner BM FILSIZE S/G
counts FILSIZE F/G
• Production-supporting services AMR-G
PROWARP
KARL MAYER WARP PREPARATION 22 / 24  

OUR PRODUCTS
OVERVIEW

GN-1 – Standard creels

CREEL
GM – Magazine creels
GD – Swivel-frame creels
GW – Carriage creels
GV – V-creels
GAR – Unwinding creels
GAM – Unwinding creels monofil
GAPP – Unwinding creels polypropylene

YARN TENSIONER KDF-2

KDF-B
KFD-SP
KFD-AIR
OPTOSTOP
U2V
U3V
DISCTENS
ISOTENS
MEGATENS
MULTITENS
ACCUTENSE 0°
ACCUTENSE 30°–90°

ZM-F – Direct warper for filament yarns

BEAMING AND DIRECT
ZM-G – Direct warper for glass fiber yarns
BEAMING MACHINES
WARPDIRECT – Direct warper for spun yarns
BW – Ball Warper
LCB – Long Chain Beamer
BM – Beaming machine

NOV-O-MATIC – Automatic sectional warper

SECTIONAL WARPERS
PROWARP – Sectional warper
ISOWARP – Sectional warper

MULTI-MATIC (MM) – Warp sampling machine

WARP SAMPLING
GIR-O-MATIC (GOM) – Warp sampling machine
MACHINES

PROSIZE – Sizing machine for spun yarns

SIZING MACHINES
ISOSIZE – Sizing machine for spun yarns (old SMR-SP)
FILSIZE S/F
FILSIZE S/G
FILSIZE F/G

AMR-F – Assembling machines

ASSEMBLING MACHINES
AMR-G – Assembling machines

PRODYE
INDIGO DYEING UNITS
24 / 23 WARP PREPARATION KARL MAYER

SHIRTING SHEETING DENIM HOME TEXTILES WOOL SILK FILAMENT TECHNICAL GLASS TECH- GLASS ELEC-
TEXTILES NICAL SECTOR TRONIC SECTOR
KARL MAYER Worldwide

Europe Germany Obertshausen, Chemnitz, Naila Italy Mezzolombardo Switzerland Uzwil UK Shepshed
Asia China Changzhou City, Hong Kong India Mumbai, Ahmedabad Japan Fukui-City
North America USA Greensboro

© KARL MAYER Textilmaschinenfabrik GmbH

We-A-1125/1/10/15

Brühlstraße 25 . 63179 Obertshausen . Germany

www.karlmayer.com

The information provided in this document contains merely general descriptions or characteristics of which may change as a result of
further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the
terms of contract. Availability and technical specifications are subject to change without notice. All rights reserved.