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  4. #218 Inside KARL MAYER TIC: Full Textile Innovation Centre Tour Warp Knitting to Warp Prep
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.

Visit Our Website:

Website 1: https://www.dersocialceo.com

Website 2: https://www.compositeslounge.com

Website 3: https://www.imbeo.de

Website 4: https://www.contentcreatorclub.de

Follow Us: LinkedIn

/ imbeo 

/ content-creator-club 

/ compositeslounge 

/ der-social-ceo 

Hashtag:

#Composites360OnTour #JECWorld #IlkayÖzkisaoglu #JECWorld
#CompositeIndustry

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