Germany’s leading developer of perfect solutions for warp knitting, technical textiles, and warp preparation for weaving, has announced that Karl Mayer Rotal, its Italian subsidiary, has seen a boost in its denim business with its PRODYE-S and PRODYE-R indigo dyeing machines. Karl Mayer Rotal offers one-stop solutions for slasher and rope-dyeing.
Compared to conventional machines available on the market, the PRODYE-S and PRODYE-R indigo dyeing machines consume less water, produce less waste and enable deeper, brighter indigo shades to be produced. The dye add-on as a percentage of the total yarn weight is 5.5 per cent maximum. This warp preparation equipment is also highly productive. The PRODYE-S can double output when processing lightweight denim. The market has been extremely impressed by the performance offered by Karl Mayer Rotal’s indigo dyeing machines. Demand has been increasing continuously since 2015, and has been especially high this year. Turkey, in particular, has placed a large number of orders.
Turkey is a lucrative market for Karl Mayer Rotal. Many large denim producers there are already working with the PRODYE-S machine and have placed follow-up orders this year. Follow-up orders have also been received from companies in Mexico. Machines have also been delivered to companies that are new to this technology – in Turkey and Iran as well. Turkish companies are also contributing to the success of the PRODYE-R. This rope dyeing machine was only delivered in May 2017. It was sent to Algeria as part of a large project, under the auspices of TAYAL, a joint venture involving the participation of the Turkish company, Taypa.
What makes PRODYE so interesting for the denim sector is that it is based on well-thought-out components. One of these innovative elements is the Double Vario dyebath, which operates on the basis of a well-thought- out cross-flow system for perfect dye liquor circulation to give a uniform dyeing result. Additionally, the Quick Oxidation zone operates with temperature-controlled air flow to guarantee uniform dye uptake. Rejects are also reduced and the colour tone of the warp yarn sheet is more uniform than with conventional techniques.