As the world’s leading manufacturer of circular knitting machines, Mayer & Cie. invests enormous resources into development, with the aim of supplying machines both for niche markets and also for high-volume producers which offer decisive benefits. An example of just how successfully it has pursued this development policy in the bulk production market is currently being provided by the Relanit 4.0.

High performance continuous single jersey production
There is no single jersey machine currently available on the market which knits more than the Relanit 4.0. The speed factor (calculated by multiplying speed by diameter) reaches an amazing SF 1,500. Four feeders per inch and a speed of up to 2 metres per second represent an exemplary standard of performance. Added to which is the giant frame for fabric bales of up to 1,200 mm in diameter (adding up to a good 225 kg of fabric with 22”) – designed to fit in with the requirements of modern dyeing plants. Whether in bodywidths from 15“ or up to 36“ in diameter – the Relanit 4.0 comes out on top every time in terms of performance, volume and profitability. 

The tape speed and consequently yarn input are controlled automatically by servo-motors. The knit-on aid designed to simplify start-up after yarn breakage is actuated by pressing a button. The newly developed Mayer Cleaning System (MCS) is a standard feature of the Relanit 4.0. With MCS, the accumulation of lint in the cylinder area is drastically reduced. As a result – depending on the yarn used – needle life is doubled or even trebled.

Yarn: Cost factor and performance brake
If only because of the high production volumes involved, yarn as a cost factor plays a decisive role with the Relanit 4.0. Yarn breakage and associated faults in the fabric as well as standstill periods are clearly counterproductive. In order to reduce yarn breakage, better quality yarns are often used which are not strictly necessary in terms of the produced fabric. Another tactic is to reduce machine speed and so cut back on potential productivity. Both of these are costly compromise solutions which are becoming ever less acceptable in the market.

Relative movement technology saves costs and increases productivity
The performance limits achievable in the field of circular knitting are determined to a large degree by the yarn. Yarn is able to withstand only a certain level of stress before it reaches breaking point. Consequently, if it is possible to reduce this level of stress, yarn breakage during stitch formation can be minimized and at the same time rotational speeds increased. This realization formed the impetus for the development of relative movement technology, which was patented by Mayer & Cie. By developing the relative movement of sinkers to needles, it was possible to halve the number of yarn deflection points passed by the thread during the knitting process. As each deflection signifies friction and so enhanced yarn stress levels, clearly relative movement technology with only four deflection points in the stitch formation zone (as against eight deflection points in conventional single jersey production) brings about a decisive relief of the stress to which the yarn is exposed. These benefits were fully implemented in the Relanit 4.0, and are a reason for the high speeds of 50 rpm which are achievable with a 30 inch diameter in continuous operation.

Yarn input controlled by servomotors
A high performance machine like the Relanit 4.0 necessitates positive yarn input. Mayer & Cie. controls this 100% positive yarn input by means of servomotors, whereby positive locking power transmission ensures a constant level of tension in the yarn feed belt without any danger of slippage.

Output and needle wear
The higher the output, the higher the needle wear. Mayer & Cie. has long since discovered an intelligent technology to defy this logical outcome. In all Mayer & Cie. machines, positive needle guidance and the gentlest possible deflection of the thread in the cams help reduce needle wear and prevent faults in the fabric.

This principle has been further optimized in the Relanit 4.0. The needle butts run smoothly with minimal friction in a completely closed track. The machine also features extremely flat cam angles, offering the benefit of further extended needle life. Smooth-running needles plus high output add up to enhanced operational reliability and optimum fabric quality. Yet another special feature of this machine: the stitch-forming length is also influenced by raising of the sinkers, ensuring reliable stitch press-off even with extremely lightweight fabrics. 

Fabric bales up to 1,200 mm diameter or 225 kg
Modern dyeing and finishing plants are capable of processing larger fabric bales than those customarily produced on circular knitting machines. The high performance of this machine series carries on through to further processing operations, as the Relanit 4.0 offers a giant frame capable of accommodating fabric bales up to 1,200 m in diameter, saving not only time and unnecessary wastage, but eliminating the need for sewing on. The tried and tested, positively controlled mechanical take-down guarantees precise winding at a constant level of tension from the beginning to the very end of the fabric bale.

Performance down to the last detail
Alongside the features already described, the Relanit 4.0 also comes with a knit-on aid as standard. The Relanit 4.0 is quickly up to speed again after a yarn brakage by simply pressing a button. The machine cooling system provides protection against overheating, and the newly developed PCB (Processor Controlled Brake) system guarantees smooth, gentle braking of the machine down to a standstill.

High performance plus pattern variety
The Relanit offers the complete range of a 4-needle machine: Plain single jersey, fleece, wide-ranging stitch combinations and 4-needle structures. Mayer & Cie. provides impressive proof that high performance does not have to mean compromising on quality. Anyone who knits with the Relanit 4.0 cannot help but be impressed.

World innovation: Mayer Cleaning System (MCS)
Relanit technology offers full access to the needle bed, and consequently also simple threading up. No lint is able to fall into the fabric tube and soil the finished fabric. But there is no way to avoid lint in the needle and cam area. This naturally increases friction, places strain on the needles and can result in faults.

Mayer & Cie. has developed the MCS system, which substantially reduces lint formation in the needle and cam area by means of air flow. Atmospheric air is extracted and forced out at high pressure through the cam segments in an upward direction. Seals between the cam segments prevent the air escaping to the side. Lint and dust are removed or prevented from penetrating in the first place. MCS has proven so successful in practice that plans exist to use the system in other Mayer & Cie. high-performance machines also. Experience has shown that the service life of needles and sinkers can be extended by between 30% and over 100% using MCS – depending on the yarn types used.

Summary
The operational reliability, output and productivity of the Relanit 4.0 place it in a unique position. The Relanit 4.0 has helped to add to the attraction of circular knitting, particularly given that its extremely high output is coupled with outstanding quality. This machine is offered in a bodywidth diameter for body widths from 15“ and up to 36“ in machine gauges 18 to 28.