Germany-based Karl Mayer Textilmaschinenfabrik GmbH has developed a sizing machine that economically processes short warps while offering performance comparable to that provided by conventional sizing machinery. Compact Size joins the Gir-O-Matic sample warping machine as part of Karl Mayer's warp-preparation solution for flexible, efficient production of short warps, reflecting a trend — especially in high-fashion markets — toward smaller product runs. The machine was first introduced in Italy, where it has met with success.


"Textile companies can use our short warp sizing machine to try out and examine new samples easily and efficiently, and small orders can also be produced economically," said Enzo Paoli, managing director, Karl Mayer Rotal, the company's Italy-based subsidiary. "What is more, the 'Compact Size' produces much less waste compared to other systems available until now, and a warp of usable quality is produced right from the very first metre."

Compact Size features a space-saving design comprising two levels. At floor level, the take-off device, sizing system and beaming machine are arranged in a line. A ladder is used to reach the second level, which includes an infrared (IR) air dryer, subsequent cylinder dryer and vertical sub-drying zone also arranged in a line. The machine has a capacity of 15 meters with the drying machine and 6 meters without it. Sizing agent requirements are reduced, and there is a reduced incidence of stop marks and waste yarn.


The sizing agent can be applied to the warp yarn either via conventional hot size application by spraying the size onto the material or using cold size application via  double kiss rollers. Each system has available a separate unit equipped with its own circulation system and different heat concepts.

Drying is optimized by a combination of air/IR drying and use of the contact cylinder dryers of the residual dryer. The drying zone includes a 240-kilowatt gas heater that offers drying performance of 40 to 50 percent at 60-meters-per-minute processing speed. The system cools down quickly after it is turned off, thereby minimizing over-drying.

The residual dryer comprises a cylinder drying system that ensures smooth yarns and accurate yarn-tension setting in the wet and dry zones. Each cylinder has its own motor drive system, which eliminates overstretching of the yarn. A steam jet pump is used to recirculate the cylinder steam, which provides for increased heat transfer and drying efficiency. Benefits of this recirculation include uniform temperatures, constant temperature control and minimal condensate in the cylinders.