The biggest single cost factor in the circular knitting factory is the yarn.
It is simply the high production volumes involved which make yarn a decisively important cost factor in todays circular knitting factory. Even assuming that purchase prices have reached their lowest level, significant rationalization reserves still wait to be exploited in production. Due to the high costs of yarn, thread breakage and associated knitting faults are naturally counterproductive. To reduce the instance of yarn breakage, higher yarn qualities are frequently used which are not strictly necessary from the point of view of the fabric being produced. Another tactic frequently used is to reduce machine speed, which significantly cuts down on productivity. Both courses of action are costly compromises which the market is becoming ever less able to afford.
Reduced yarn stress during knitting helps avoid thread breakage.
By its very nature, circular knitting is highly productive and therefore the most cost-effective way of producing textile surfaces. The reason for this lies in the continuous circular movement. Development engineers have always striven to extend the mechanical limits of revolutionary speed. In the case of circular knitting, the yarn is the factor which sets the limitations here. A thread has a certain stress limit at which it ruptures. Consequently if a way can be found to lower the level of stress, yarn breakages will be reduced to a minimum, resulting in higher rotational speeds. It was this underlying precept which culminated in the development of relative movement technology. By causing the needles and sinkers to move in relativity to each other, it was possible to halve the number of yarn deflection points occurring during the knitting process. As every deflection equals friction and thus increased stress on the yarn, it is easy to see how relative movement technology with just 4 deflection points in the stitch forming area (compared to 8 deflection points using conventional knitting single jersey technology) was instrumental in bringing about a decisive reduction in yarn stress.
Relative movement technology a quantum leap in circular knitting technology.
Mayer & Cie. was quick to recognize that relative movement technology represented a major breakthrough in single jersey circular knitting production. The leading manufacturer of circular knitting machines exhibited the worlds first circular knitting machine featuring relative movement technology at the 1987 ITMA in Paris. In the meantime over 5,000 Relanit circular knitting machines have been sold worldwide, and relative movement technology, still implemented exclusively by Mayer & Cie. with its Relanit series, has long since become the established standard for single jersey production.
Relanit an investment that pays dividends
In practice, knitting manufacturers assume an average of 5 faults per hour using conventional single jersey circular knitting machines. These are made up of 3 faults caused by thread breakage and 2 by oil stains on the fabric.
Long years of practical experience have shown that a Relanit circular knitting machine, in contrast, will produce on average a maximum of one fault per hour as a result of thread breakage. Oil stains resulting from oil-soaked lint have been practically excluded due to the fact that the Relanit does not have a separate sinker and sinker cam ring. This design feature prevents the lint falling to the outside and so coming into contact with the knitted tube.
An average of 0.5 metres of waste fabric is generally anticipated on every occurrence of a fault. Black on white, this means that a Relanit will save the circular knitting factory around 2.0 metres of waste fabric hour on hour. Added to this are a good 80% fewer standstill periods compared to conventional single jersey machines.
Due to the minimal stress exposure of the yarn, it is possible to more precisely equate the yarn quality to the fabric to be produced without taking account of mechanical processing limits another significant money saving factor. And as a rule knitting takes place at substantially higher speeds on a Relanit in direct comparison to conventional machines. All these factors taken in conjunction quickly add up to amounts to the tune of several thousands of US dollars year on year.
Relanit the current single jersey standard for most fields of application.
Relanit has long since become the established single jersey standard in the knitting industry today. The fabric quality is exemplary and the costs of production considerably lower. There is no single jersey machine on the market capable of greater productivity. Today, Mayer & Cie. offers Relanit circular knitting machines for a wide range of different applications.
A 4-needle machine to cover the whole range of applications: Relanit 1.6 R.
4 needle tracks with slider cams determine the wide range of different constructions. The Relanit 1.6 R knits single jersey fabrics, crepe, one-thread fleece and plated single jersey constructions. Also with striping attachment, the uninterrupted view and access to the needle bar make this the ideal machine for stripe production. The Relanit 1.6 and 1.6 R are available in diameters ranging from 26 to 34 and in gauges E12 to E28.
Full jacquard electronic capability with the 3-way technique: Relanit 1.6 E and Relanit 1.6 ER
These highly productive machines designed for the production of all single jersey jacquard and structure jacquard constructions are made particularly flexible and versatile by the full 3-way technique. With highspeed resetting made possible by their full Mayer & Cie. electronic capability, the number of feeders, relative movement technology and high speed all work together to produce an outstanding output. The addition of a striping attachment means extended patterning versatility for the knitting factory. The machines on offer come in diameters ranging from 26 to 34 and gauges E12 to E28.
Single jersey with 3-way technique with full electronic capability: The Relanit 2.4 E
The Relanit 2.4 E coupled with full electronic capability is a recipe for fast, simple and highly efficient fashion production. Diameters 26 to 34, gauges E16 to E28.
Mini-Jacquard at the press of a button: Relanit 2.4 SE
For single jersey mini jacquard, structures and plated fabrics, the Relanit 2.4 SE offers a highly interesting alternative. Patterns are quickly reset electronically and knitted mechanically: Ultra flexible, ultra simple and highly productive even for small batch jobs. Cylinder diameters 26 to 34, gauges E18 to E28.
Custom-tailored for fashion yarns: Relanit 3.2 II
Synthetic yarns also used in combination with elastomers are a determining factor in defining fashion. The Relanit 3.2 II is the absolute specialist in this field. Using special machine settings, it is capable of taking cotton as well as synthetic yarns easily in its stride with the accustomed high standard of quality in single jersey, 4-needle structures and single plated.
High-performance single jersey with the Relanit 4.0
There is no other single jersey machine capable of knitting more than the Relanit 4.0. The speed factor (calculated from rotational speed x diameter) reaches SF 1.500.
Added to this is the benefit of the Gigant machine frame for fabric bales up to 1,200 mm in diameter (a good 250 kg for a width of 22) in keeping with the production capacity of modern dyeing plants. Whether in body widths from 15 diameter or up to 34 and in gauges from E18 to E28- the Relanit 4.0 is the absolute top runner in terms of output, volume and profitability. The tape speed and therefore also the yarn feed are automatically controlled by servomotors. The casting-on aid is activated at the press of a button following a yarn breakage. The newly developed Mayer Cleaning System (MCS) is a standard feature of the Relanit 4.0. MCS and substantially reduces lint build-up in the cylinder and dial area. The result: 2 3 times longer needle life.
Relanit 0.8 the specialist in technical textiles.
It goes without saying that the specific benefits of relative movement technology make it ideal for compact knit goods, even with fabrics using spun steel fibres. As a result, the Relanit 0.8 is capable of manufacturing knitted fabrics made of copper, steel and silver wire, glass fibres, carbon fibres, carbon etc. also in conjunction with cotton. The fields of application are wide ranging, including for instance protective clothing, car upholstery fabrics, medical textiles, home textiles and the furniture industry. The Relanit 0.8 is offered with a 22 diameter and in gauges of E12 to E16. Other versions are available on request.
Summary
Relanit movement technology has long since become established as the accepted single jersey standard. The machine range on offer today is so varied that it covers practically every conceivable field of application. Given the enormous success of the technology and the large number of machines produced, the price difference compared to conventional single jersey machines is by no means as great as it was during the early years.
Given the cost saving potential it offers in terms of reduced yarn consumption due to fewer faults, simple operation and high performance, it pays to invest in Relanit technology. With a payback period substantially lower than for conventional single jersey knitting machines, this technology ideally addresses current market demands and offers significant scope for effective cost management.
