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FL 20/16 set to transform Indian sari fabric production
Dec '12
By creating a new range of patterns on the FL 20/16, the product developers at KARL MAYER have succeeded in developing something new and innovative that is set to revolutionizes the production of sari fabrics.

The trendsetting fabric has a unique appearance and can be produced extremely efficiently. The new fabrics are as beautiful as conventional saris and can be produced in a single piece, so that they can be manufactured extremely economically. The pattern, together with the sections that are patterned with specific designs, such as the elaborately decorated shoulder piece at the end, which is known as the pallu, are worked directly into the fabric by the FL 20/16.

For simpler patterns, the embroidery process can now be dispensed with - a procedure that has always been carried out on net saris having marquisette or tulle constructions. All that has to be done is to hem the edges or – as on the model shown here (Fig. 1) – use hemming tape as another option to create a fabric with a perfect drape.

The increased performance of the FL 20/16 is the result of its technical features:
• Four ground guide bars and 16 pattern guide bars, each with EL drive,
• the KAMCOS computer platform equipped with the Motion Control/Multi Speed facility, which permits the speed of warp yarn delivery and fabric take-down to match the specific requirements of the pattern.
When producing a complete sari having a length of 5.50 m, the computer facilities of the FL 20/16 can handle the data sets for working up to 17,100 knitted rows. At a working width of 132", this results in two matching saris being produced next to each other.
Embroidery-like effects:
The pink and gold sari shown on this page has filigree, lattice-like ground with a dense, all-over pattern, whose relief-like characteristics make it look as if it has been embroidered. The multifaceted design is made up of diamonds, ovals, dots, dense stripes and, in the pallu section, teardrop paisley motifs.
This produces an effective ensemble, which is created by the 16 pattern bars on the marquisette-like ground construction. The three-dimensional design is produced by placing the pattern bars in positions 1 to 16, so that they are in front of the four ground guide bars. Of course, as well as graphic patterns, floral patterns and similar decorative effects can also be produced.
Materials that have been designed to provide comfort support this attractive look. For example, polyamide in the ground makes the fabric feel soft against the skin, whilst polyester is used to work the pattern. These materials, in combination with soft-touch finishing, produce a fabric that is both beautiful and extremely comfortable to wear.

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