PROSIZE

Your Benefits
 

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  Size saving – the turbulent size application and the sponge effect allow reduction of the size add-on up to 10%

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  Minimum yarn stretch – the short wet-application zone with 100% bonded yarn transport and SoftDry system ensure lowest yarn elongation in the sizing process

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  High weaving efficiency – top weaving performance through absolute size liquor homogeneity, low hairiness, less dust and no stop marks
   

   

FEATURES & TECHNOLOGIES 

Get the most out of your machine with our cutting-edge systems and features

CASCADE

CASCADE  is our patented steam-condensate system, which offers innovative inline energy recycling, reducing steam consumption in the sizing process by up to 7%. This cost-effective solution focuses on reusing and recirculating process steam in drying cylinders, significantly lowering the required process energy. This new system generates 'recycled steam' which is utilized at medium pressure and temperature in the last section of drying cylinders, at the desired residual value. A sensor provides continuous data on the amount of steam circulating in the system, enabling accurate calculation of CO2 emission reduction. On average, each ton of generated steam produces 0.23 tons of CO2 (based on various heating methods including fossil fuels, natural gas, and oil). Our system helps reduce this environmental footprint.

Smart Size Box

The sizing box is the heart of the machine and operates in the most aggressive working conditions, which include high temperatures, high squeezing pressure and chemical aggression. The sizing box is essential for the machine's functionality and any critical failure can cause unexpected downtime, which can disturb the programmed sequences and cause higher maintenance and repair costs. To address this, KARL MAYER has developed the SMART SIZE BOX system as a predictive maintenance tool.

Predicting Failures & Reducing Costs

• Analyses motor parameters, vibrations and temperatures of roller bearing
• Prevents unplanned downtime and cuts routine maintenance costs

Enhanced Monitoring

• Automatic monitoring to detect malfunctions and abnormalities

• Identifies gaps in routine maintenance

Providing Actionable Insights

• Recommends optimal maintenance schedules
• Estimates performance of key assemblies
• Delivers instant alerts via customer portal

SoftDry Technology

This technology is driven by single-drive motor system for the minimum yarn stretch and equipped by a fully self-adjustable algorithm for yarn motion control which allows a perfect yarn guiding over the whole drying phase. This assures an equal distribution of the yarn tension between cylinders, avoiding friction.

Unique size box concept

Lowest use of size add-on and highest cover factor, reduced maintenance, all bearings are outside of the size liquor, bonded yarn guidance, easiest accessibility to all core components of the size box.

Lowest production costs

Short and controlled wet application zone with an efficient filtering system assure size saving up to 10% and no over-sized warps even after long down times. Less cross ends and lapper formation. Production speed up to 200 m/min.

Machine Details:

Back Creel Dimension
Working Width
1.800–2.800 mm 

Diameter
800 / 1000 / 1250mm (1400mm option)

Working Width in Size Boxes
1800-2400mm HSB 1800-3200mm VSB

Modular Drying Cylinders
4-24 drying cylinders (FL and OH execution)

Headstock Dimension
Working Width
2600 / 3100 / 4000mm

Diameter
1000 / 1100 / 1250 mm

Headstock Performance
6000N at 160 m/min (standard)
8000N at 160 m/min (option)
6000N at 200 m/min (option)
12.000N at 160 m/min (option)