Overall view of the DS Opto-EC.
Overall view of the DS Opto-EC.
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Karl Mayer’s DS Opto-EC is the first warp preparation machine for the warp knitting sector that can offer both: direct and sectional warping. This innovative machine combines sectional warping with direct warping on the basis of a universal hybrid principle. The result is maximum flexibility and economic viability when producing warp beams for warp knitting.


Direct and sectional warping on a single machine


The DS Opto-EC processes non-stretch filament yarns to produce warp beams having a wide band width. Conventional sectional warp beams with long running lengths, having a width of 21” and a diameter of 30", can be produced efficiently by the direct warping process. If short warps are needed for product development, or if small runs have to be worked, the DS Opto-EC offers easy handling and low costs in the sectional warping mode.


Furthermore, the warp-for-warp technique enables processing tests to be carried out on expensive yarns economically. Expensive yarns can also be used efficiently when producing high-quality sectional warp beams for the current production operation. These advantages are the result of the small number of packages needed. In addition to the financial advantages, the small number of packages required also saves space.


The DS Opto-EC also offers advantages for cone warping when producing patterned sectional warp beams. This innovative machine places yarn sections of different colors next to each other accurately, and operates at high speed, thus producing precision warp beams efficiently.


A tandem solution: HKS 4-M EL and DS Opto-EC


The HKS 4-M EL was processing patterned sectional warp beams produced by the DS Opto-EC when it was being demonstrated at ITMA 2015. During the machine show, this high-speed tricot machine was producing a fabric having six different, attractive designs seamlessly one after the other – without stopping and at top speed.


The EL pattern drive on the HKS 4-M EL enables the pattern to be changed quickly, and virtually unlimited repeat lengths can be worked. The combined performance of the HKS 4-M EL and the DS Opto-EC enables new products to be developed economically, if required. The high-speed tricot machine also enables short runs to be produced economically, thanks to its high operating speed.


Sophisticated technology guarantees high performance


As well as being flexible, the DS Opto-EC also offers top quality in both warping modes, and enables warp knitting to be carried out at maximum efficiency. The sectional warp beams have absolutely identical circumferences, and the package build is completely uniform.


This unique level of precision owes its success to the improvements that have been made and to technology transfer. For example, the master successive band or master successive beam principle, which is a feature of weaving preparation, has been transferred to the DS Opto-EC, and the conventional sectional warping process has been optimized.


The creel system, yarn feed and braking synchronization are all perfectly coordinated during cone warping. A warping carriage, which moves parallel to and across the drum axis, guarantees exact positioning of the yarn sheet on the warping drum, and the band build-up is monitored by a laser and computer.


During beaming, dancer rollers control the yarn tension and thus ensure that beams having the same circumference are produced. The DS Opto-EC also operates extremely quickly – the maximum speed during direct warping is 1,000 m/min and during sectional warping is 600 m/min.


On stage at ITMA Asia


According to Karl Mayer, a DS Opto-EC was sold to a highly innovative customer in Asia. The machine was delivered in March of this year, and the client is currently testing the new machine.


The DS Opto-EC will be displayed in operation at ITMA ASIA which is being held from 21-25 October 2016 in Shanghai, China. Karl Mayer (China) will be holding an in-house exhibition in Wujin to coincide with the fair, and this new warping machine will be on show then.