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Karl Mayer: Short-Run Solution

The GIR-O-MATIC short-run warper enables quick setup of short warps and adds flexibility to weaving operations.

Jim Borneman, Editor In Chief

A lthough the name Karl Mayer is synonymous with warp-knitting machinery, warp-preparation technology has been a significant part of the product mix since the company’s delivery of its first warper in 1950. The history of Germany-based Karl Mayer Textilemaschinenfabrik GmbH stretches back to the company’s first workshop in 1937 and first factory in 1940. Today, it has 2,650 employees worldwide and annual revenues of $350 million.

Mark Smith presents an overview and live demonstration of Karl Mayer's GIR-O-MATIC to open-house guests.

GOM Presentation
Mayer Textile Machine Corp. President Tony Hooimeijer recently welcomed guests to the company’s Greensboro, N.C., facility — one of two in the United States — to view a demonstration of the GIR-O-MATIC (GOM) short-run warper.

Introduced at ITMA 2003 in England, the GOM has made weavers rethink the challenges of short-run warps, which traditionally have been made with single-end warpers or using a sectional warper that incurs steep surcharges for the customer. The GOM, as part of a new solution for sample and short-run production warps, adds flexibility and efficiency to weaving operations.

To date, Karl Mayer has installed 85 GOMs worldwide — 50 percent are in Italy — with one in Canada and three in the United States.

According to Ken Overly, sales manager, beam preparation, Mayer Textile Machine Corp., what sets the GOM apart is its ability to produce warps of up to 770 yards using one to 16 packages of yarn. The GOM allows for improved efficiencies in time, labor and yarn consumption; as well as a reduced equipment footprint — approximately 40 percent of the space necessary to run a sectional warper.

The GOM can produce blanket or pattern warps with a maximum warp width of 88 inches. Beam flange diameter ranges from 31 to 40 inches, and warping and leasing speeds are achieved at up to 1,094 yards per minute. Setup time is less than 30 minutes.


The GOM features a touch-screen monitor that has easy-to-understand icons and provides all relevant warping data while running. Error messages and on-screen help icons also are displayed. The screen enables computer-aided creeling and simple order entry. Order entry through a network and computer-aided design program interface also is possible.

Compared to Karl Mayer’s single-end warper, the GOM features a yarn-guide finger rather than the traditional guide, as well as a broader and deeper warp buildup. The rotating creel increases the speed of laydown by eight times. Programmable warp patterns are achieved with hands-free operation and fully automatic leasing. A pre-beamer option also is available for uninterrupted production and increased flexibility in controlling warp tensions.

Mark Smith, warp preparation sales manager, North and South America, United Kingdom and Pakistan, Karl Mayer, presented the live demonstration of the machine at the event. “We understand the pressure you [US weavers] are under,” he said. “We are trying to introduce a machine that can create new opportunities. There is a future in the US market — we need to be flexible.”

November/December 2005