What does a full-scale textile innovation environment look like—from yarn preparation to finished applications?

In this episode of #Composites360onTour, Ilkay Özkisaoglu (Thought Leader in Advanced Materials & Co Founder of Composites Lounge) conducts a complete engineering walkthrough of the KARL MAYER Textile Innovation Centre (TIC) in Obertshausen, Germany, recorded during the Grand Opening on April 21, 2026.
This is not a showroom visit.
This is real industrial textile production with full process transparency.

🧵 Warp Knitting: Speed, Precision, Versatility
The tour begins with KARL MAYER’s HKS tricot machines:
• HKS 3-M EL PLUS (E14) → coarse gauge for thick yarns and open structures (footwear, medical, technical textiles)
• HKS 2-SE (E40, 4100 rpm) → fine gauge elastic fabrics (sportswear, swimwear)
• HKS 3-M EL (186", E28) → versatile applications including automotive roof linings
• HKS 4-M EL → extended pattern capabilities for furniture and technical fabrics
Key insight:
👉 Operators validate quality at low speed (“turtle”) before switching to production mode (“rabbit”).

🧶 Raschel Technology: Pattern & Function
The second part covers Raschel machines:
• MJ 92/1 F (Jacquard) → lace structures with post-processing (clipping yarns)
• RS 2 NET → net production for agriculture and sports
o integrated film-to-yarn conversion (FTL aggregate)
o machine produces its own yarn from raw film
• TM 4-TS EL (210") → terry towel production with brushing for loop formation
Key innovation:
👉 Direct transformation from raw material to final product within one system.

🏭 Inspiration Hub & Applications
The TIC integrates engineering with application:
• Textile archive with up to 100 years of developments
• Pattern cards including machine parameters
• Applications across:
o workwear
o medical
o defense
o fashion
Engineers can: 👉 reverse-engineer fabrics
👉 reduce development risk using proven setups

⚙️ Warp Preparation: Where Quality Begins
With Tobias Kraus, the focus shifts to warp preparation:
• Creel systems with up to 2000 packages
• PROWARP HT sectional warping
o width: 3600 mm
o speed: up to 1000 m/min
Critical controls:
• FILGUARD monitoring → stops machine immediately on yarn break
• Uniform yarn tension across all ends
• Controlled beam build-up
Advanced system:
• MULTIMATIC 128
o 128 yarn guides for color and pattern flexibility
Core takeaway:
👉 Every fabric quality is defined in warp preparation.

📍 Why This Episode Matters
The TIC provides a complete textile value chain in one place:
• yarn preparation
• fabric formation
• application validation
For textile engineers and operators, this means: 👉 real machine insight
👉 process understanding
👉 quality control visibility

🎙️ Featuring
• Ilkay Özkisaoglu (Composites Lounge)
• Melanie Bergmann (KARL MAYER)
• Tobias Kraus (Warp Preparation Expert)

🔜 Up Next
A second episode will focus on technical textiles and composite applications.

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