At ITMA ASIA 2026, KARL MAYER will demonstrate its expertise in processing staple fibers during warp preparation and will return to where this technology belongs: the Weaving Hall, at Booth 3/A24. The focus here will be on the latest-generation WARPDIRECT direct warping machine, featuring various yarn tensioners, as well as the sophisticated HSB Size Box – the centerpiece of the innovative PROSIZE sizing machine. Both technologies are aimed specifically at manufacturers of high-quality goods in the commodity sector.
„Our machines produce warp beams of the highest quality with high process efficiency. This offers particular advantages to textile manufacturers who are focused on generating real added value in a highly competitive market,“ says Enzo Paoli, President of the Warp Preparation Business Unit at KARL MAYER.
WARPDIRECT: With the Highest Speed to Precision Warp Beams
Since its launch at the end of last year, the WARPDIRECT 2.0 has already been successfully deployed worldwide. Its performance is particularly valued in India, but also in China and Europe. Its strengths include identical warping lengths for all warp beams and high production output. In practice, warping speeds of up to 1,200 m/min are achieved.
In addition, the current machine version stands out thanks to an upgrade to the press roll system. The change from hydraulic to electric operation reduces maintenance requirements while ensuring precise warping quality. In combination with an optimal yarn depositing device, this results in completely cylindrical beams with precise yarn arrangement.
Additional features enhance ease of use and process reliability, including:
- Smart-Riet for automatic reed adjustment to the warping parameters
- Yarn- and lap-protecting kick-back function
- Automatic uncrossing function for re-establishment of the thread arrangement immediately after start-up
Four Yarn Tensioners, Many Possibilities
KARL MAYER demonstrates just how flexibly the WARPDIRECT can be adapted to different yarns and applications by showcasing various yarn tensioning systems on a parallel creel. The following will be presented:
- The yarn tensioner OPTOGUARD with optical yarn monitoring system as the ideal solution for highly efficient warping of staple fiber yarns from the V-creel
- The electronic tension system YTC 2000 with yarn tension control as standard in the denim sector, are now also suitable for other applications following an upgrade
- The universal double disc-type yarn tensioner ISOTENS suitable for a wide range of materials, from filament yarn to silk, featuring a new yarn break shut-off mechanism
- The disc-type yarn tensioner MEGATENS for coarse and technical yarns, also featuring a new yarn break shut-off mechanism
HSB: Less Size Add-On, High Performance
With the HSB Sizing Box, KARL MAYER presents another highlight for high-quality and cost-effective warp preparation. Like all Size-Box variants of the PROSIZE series, the HSB achieves a cover factor of up to 100% thanks to its intelligent process concept, while also offering a high filling ratio, bonded yarn guidance, and reduced size add-on consumption. Savings of up to 10% can reduce costs and environmental impact during both sizing and subsequent desizing.
Additional benefits include low maintenance requirements, easy access to core components, and a maximum sizing speed of 160 m/min. Speeds of up to 200 m/min are available as an option.
Thinking Beyond Weaving: WovenLike WARP KNITS
Another eye-catching feature of the presentation shows that a visit to the KARL MAYER booth 3/A24 doesn’t have to end with traditional weaving: a trendy collection of WovenLike WARP KNITS. These exclusively curated fabrics combine the look and feel of woven fabrics with the characteristic advantages of warp knitted textiles, including, in particular, highly efficient production, easy care, wrinkle resistance, and exceptional comfort.
With this, KARL MAYER invites weaving customers in particular to think beyond familiar textile structures and technologies and discover new product possibilities.
