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TongDe speeds production with Karl Mayer's Lace.Express
Oct '17
TongDe speeds production with Karl Mayer
FuJian TongDe Knitting, a leading warp knitting fabric producer from China, has become one of the leading manufacturers in the commodity sector for Allover Lace with the Lace.Express machine from Karl Mayer. Karl Mayer is Germany’s leading manufacturer of perfect solutions for warp knitting, technical textiles, and warp preparation for weaving.

In 2003, FuJian TongDe Knitting Co. Ltd purchased their very first chain link lace machine for producing lace bands. By 2011, they had gradually expanded their lace production capacity to a total of 37 sets of various types of Karl Mayer lace machines.

In late 2012, when the lace business was booming, Chen Guang Cheng, the managing director of FuJian TongDe Knitting Co. Ltd, decided to upgrade their production line by investing in Karl Mayer 134” MJ59/1B high performance jacquard lace machines and at the same time they successfully sold most of the old generation Karl Mayer SU lace machines.

At the end of 2016, Karl Mayer launched the first Lace.Express machine, OJ 59/1 B, 210”, a wider lace machine for the production of Allover Laces. In 2017, the production capacity from TongDe Knitting has reached 400 tons per month. The massive innovative output from their large R&D team has made TongDe Knitting become one of the leading manufacturers in the commodity sector for Allover Lace.

The main reasons for choosing Karl Mayer machine was high production rate combined with operational stability and reliability of the machine. We can learn directly from the experience of TongDe Knitting by comparing the performance statistic of the Karl Mayer OJ 59/1 B, 210”, and a locally manufactured lace machine from the competition. In a direct comparison between the OJ 59/1 B 210” and 268” locally manufactured lace machine, the output from both machine types is in the range of 10-13 tons.

The Karl Mayer machine can run at a steady high speed of 900 rpm for actual production when using good quality yarns, prepared correctly for the machine and with the right settings. This in turn gives stable quality with less material wastage and second quality.

210” machine has a smaller footprint and uses less floor space than a 268” machines and lowers the air conditioning requirements which helps lower the production cost. A more stable running machine requires less operators to look after the workshop reducing the total operating cost.

A further brilliant idea from TongDe Knitting was to connect the operating platforms of all machines to a closed construction. This makes it easier to load the high level creels for all the machines in the whole workshop using a dedicated team of workers. The Lace Machine operator only has to look after the knitting area. By separating the function of machine operation and yarn loading, there is a great increase in efficiency for the whole workshop which helps to bring down the manufacturing cost. (GK)

Fibre2Fashion News Desk – India

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