KARL MAYER PROSIZE® – A breakthrough innovation in sizing

The process of coating a yarn surface to improve weaving performance is called sizing. Sizing is the ‘the heart of weaving’. It is the most important operation to attain maximum weaving efficiency for all spun yarns and filaments. Being a complex process the variances encountered during the sizing are manifold and can make or break the weavability of yarn. A.T.E. presents KARL MAYER’s breakthrough innovation in sizing technology – PROSIZE® – development of a new machine that could improve several aspects of sizing process. 'We don't size yarn - We PROSIZE it!'

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1. KARL MAYER PROSIZE ® – A breakthrough innovation in sizing A.T.E. Enterprises Private Limited V2.0 May 2017

2. What is sizing ? The process of coating a yarn surface to improve weaving performance is called sizing. Sizing is the most important operation to attain maximum weaving efficiency for all spun yarns and filaments. Sizing is called ‘ the heart of weaving’. Objectives of sizing Optimum end breaks in weaving size add-on To improve the warp yarn strength , smoothness and abrasion properties without affecting the elasticity of the yarn To improve weaving efficiency by reducing the warp breaks during weaving Objectives: To provide a protective and lubricating coating ( size ) to the surface of the yarn to enable the yam to withstand abrasion and stress which occurs during the weaving process

3. It is said that well sized is half woven ; however, the variances encountered during the sizing are manifold and can make or break the weavability of yarn The principle sizing factors influencing weaving efficiency are: ● Size pick-up ● Hairiness ● Yarn stretch The increase in strength and abrasion resistance of yarn mainly depends on: Size recipe mixing Size recipe penetration in yarn Size recipe pick-up on yarn Over all sizing conditions The application of size recipe is chosen based on the count of yarn, blends, twist and uniformity of yarn as well as the construction of fabric to be woven Sizing of warp sheets requires strict control and monitoring of the consistency of the size recipe, the sequence of its mixing, level of size recipe in the saw box, squeezing pressure, viscosity and temperature Sizing – a complex process

4. To improve the weavability of warp yarn by making it more resistant to the action of high speed weaving To maintain good fabric quality by reducing hairiness, weakness and by increasing smoothness and absorbency of yarn To increase tensile or breaking strength of cellulosic yarn To increase the elasticity and frictional resistance of yarn To reduce electrostatic formation Purpose of sizing

5. Limitations of the conventional size application technology High volume of size bath : Difficult to maintain constant temperature and viscosity in all the size box’s points Limitation in the working width Not effective cleaning and filtering Limitation of cover factor/occupancy of yarn in sizing Sticky and crossed ends caused by: Not complete bounded yarn transport; the yarn is not clamped when immersed into the size liquor Free yarn passage between the squeezing zones Long yarn pass in the wet zone Stop marks problem and broken ends in case of long machine stops

6. Introducing PROSIZE® A breakthrough innovation in sizing technology

7. PROSIZE ® – what is it ? PROSIZE® is the result of a project started by Karl Mayer in 2011 for the development of a new machine that could improve all of the following aspects of the sizing process: Reduction of size add on Ensure fresh size recipe applications Increase of weaving efficiency Better ergonomics and process transparency Increased productivity The first step was to analyse the limitations of the conventional system

8. PROSIZE® – f eatures and benefits Main technology advantages Sponge effect - 3 high turbulent uniform application zones to increase the maximum warp density Lowest minimum trough volume in the market - Reduction of size liquor sewerage 100% bonded yarn transport - Y arn is driven only by the main application roller - 3 fix squeezing/clamping points (reduction of sticky & cross ends) - Yarn can reach an optimum (low) stretch. Spray bar technology - Homogeneous & controlled size transfer to the yarn. Furthermore, only cleaned and filtered size is applied to the yarn Short and controlled wet application zone: - Yarn runs only over one main driven roller - Total length of wet zone is reduced - Free yarn passage between the intermediate squeezing zones are eliminated

9. PROSIZE® – no limitation in cover factor/occupancy PROSIZE® ensures practically 100% coverage of yarn in sizing 10 kN 10 kN 40 kN

10. Through advanced control and regulating technology KARL MAYER PROSIZE® ensures perfect sizing of warp sheets with: Uniformly optimal sizing process Low hairiness on the warp yarn Lowest elongation of yarn during sizing Automatic section tension control High level of reproducibility with - - simple operations - automatic monitoring of all parameters - comprehensive recipe management Perfect sizing

11. Full accessibility to each roller. The complexity of broken end repairing is completely eliminated The operator has a complete overview of the machine process conditions PROSIZE® – vertical size box (VSB) You can see the process through a glass Ergonomics and process transparency

12. Increased working range (20 – 100%) Perfect homogeneity of the size liquor A VSB in a wide working width is the right solution to replace the double size box system PROSIZE® 2200 20 back beams 2200/1000 1 size box VSB 10 drying cylinders Beamer 2600/1000 Sizing machine suitable for all narrow width weaving machines (170 – 230 cm) Single size box system in large working width PROSIZE® – vertical size box (VSB)

13. Cylinder drier type DU New bearings and SoftDry PROSIZE ® cylinder drier SoftDry – special features The drying cylinder with SoftDry technology is a complete new design made to perfectly fit with the VSB Equipped with perfectly sealed bearings that do not need any maintenance Stronger and more modern construction SoftDry – The innovative yarn motion control during drying Even tension increase over the whole drying process

14. SoftDry – the innovative yarn motion control during drying On conventional driers, all cylinders are forced to move together by a chain transmission This doesn’t allow any yarn elongation in between the drying cylinders However , yarn is elastic, especially during the drying phase of the sizing process The rigidity of the chain and the elasticity of the yarn are in conflict As the chain always prevails, the consequence is a slippage of yarn onto one or more cylinders surface Conventional chain transmission

15. The purpose of SoftDry technology is an equal distribution of yarn tension cylinder by cylinder, leaving the yarn free to elongate or shrink according to its intrinsic properties, avoiding friction As a result, quality is enhanced and the yarn is softer. Indeed, the weaving is more efficient and chemicals consumption can be reduced SoftDry is fully self-adjustable, regardless of the type of yarn in use. It does not require any special settings, calibrations, or additional human intervention SoftDry system with 4 cylinders Y arn tension is smoothly increased, while its elasticity is preserved The smart algorithms control each cylinder the way the yarn needs SoftDry – the innovative yarn motion control during drying

16. PROSIZE® – key highlights Increase of weaving efficiency, thanks to better homogeneity and less dust Reduction of the size add on and size liquor sewerage 20% increase of yarn coverage working range Stop marks strongly reduced in length and in oversized film, also in case of long machine down-time Machine speed up to 180 m/min SoftDry system to guarantees a smooth increase of the tension and preserves the elasticity of the yarn Possible working width up to 3200 mm Size application system Inside view

17. 1 Irrelevant 2 Sufficient 3 Good 4 Important 5 Remarkable Size reduction Productivity Stop marks Quality Lappers PROSIZE® – additional benefits in grey and apparels Thanks to the 20% increase of the yarn coverage, it is possible to run most of the articles with single size box instead of double Disposal of the squeezer rollers reduce extremely the lapper formation

18. 1 Irrelevant 2 Sufficient 3 Good 4 Important 5 Remarkable Size reduction Productivity Stop marks Quality Lappers Thanks to the no-immersion system and the fine filtering, there is no “contamination” between the different colors of the yarns No stop marks or broken ends after the preparation of the front reed PROSIZE® – additional benefits in shirting

19. Running bed sheet articles in 2800 mm working width with a single size box gives a more even and uniform yarn sheet than a conventional sizing machine with double size box Completely eliminated the sticky ends 1 Irrelevant 2 Sufficient 3 Good 4 Important 5 Remarkable Size reduction Productivity Stop marks Quality Lappers PROSIZE® – additional benefits in sheeting

20. PROSIZE ® – additional benefits in terry 1 Irrelevant 2 Sufficient 3 Good 4 Important 5 Remarkable Size reduction Productivity Stop marks Quality Lappers Production speed for the pile 180 m/min No crossed ends in the terry articles (very low density)

21. 1 Irrelevant 2 Sufficient 3 Good 4 Important 5 Remarkable Size reduction Productivity Stop marks Quality Lappers Thanks to the 20% increase of the yarn coverage, it is possible to run all the denim articles with single size box instead of double No sticky ends even with high density articles Less color loss in the size liquor as no immersion system PROSIZE® – additional benefits in denim

22. PROSIZE ® – summary of benefits Size pick up reduction between 5 to 10 %, without compromising the weaving efficiency Running of bed sheet articles on PROSIZE gives a more even and uniform yarn sheet than a conventional sizing machine with double size box No crossed ends in terry articles ; even for machines running at 180 m/min Elimination of sticky ends in bed sheets Stop marks reduced in length and in oversized film, also in case of long machine stops Less dust in the dry split field and expansion comb area High viscosity range for the size liquor Highly flexible system; can run with: 2 size application points with terry articles 3 size application points with bed sheet articles

23. PROSIZE® – the complete and perfect sizing machine Worldwide references Region Asia China India Western Europe North America South America Africa Middle East + Turkey We do not just size warp…..we PROSIZE it !!! More than 68 PROSIZE® sold worldwide, including 20 in India

24. THANK YOU