INHALT
Mayer Network
We care about your future
Sonderdruck
Sonderdruck
INHALT
Mayer Network
We care about your future
Sonderdruck
Sonderdruck
3
CONTENTS
INHALT
Mayer Network
We care about your future
Sonderdruck
Sonderdruck
IMPRESSUM 01/01/2007
No reprints, neither in extracts, without authorization of the editor:
the company of KARL MAYER Textilmaschinenfabrik GmbH, 63179 Obertshausen.
Cover photo: www.photocase.com
Rights for technical modifications reserved!
4
11
16
18
INTRODUCTION
PRODUCTION OF THE NETS PAGE 4
REVIEW OF THE PRODUCTS PAGE 5
BASIC NET CONSTRUCTIONS PAGE 6
PRODUCTION OF THE NET OPENINGS PAGE 7
INCORPORATION OF FUNCTIONAL ZONES PAGE 8
KNOTLESS NETS PAGE 9
TYPES OF MATERIALS PAGE 10
APPLICATIONS
CIRCULAR BALE AND PALLET NETS PAGE 11
AGRICULTURAL NETS PAGE 12
FISHING-NETS PAGE 14
SPORTS AND SAFETY NETS PAGE 15
REVIEW OF THE MACHINES
WARP-KNITTING MACHINES FOR PRODUCING
NETS PAGE 16
YARN FEEDING
YARN FEED SYSTEMS PAGE 18
4
INTRODUCTION
Textile nets have a wide range of enduses. One of their main uses is to protect
against adverse weather conditions, in
which case, the nets are constantly subjected to many different climatic effects.
This has led to the development of many
new applications, both inside and outside.
Warp knitting technology offers a wide
range of possibilities for producing nets,
which no other technology can match.
Alongside weaving and weft knitting, warp
knitting is widely used to produce textile
substrates for a variety of applications.
Warp-knitted fabrics may be elastic or
dimensionally stable, they may have open
or dense constructions, and may have fine
or coarse structures. They can be produced as flat, tubular or three-dimensional
textiles in widths of up to six metres and
above. Besides the exceptional width of
the nets, another advantage is that the
design of the nets can also be varied
extensively, depending on the knitting process used and the construction.
Warp knitting technology enables the individual products to be adapted to suit specific requirements. All the machines can
produce single or multiple webs, and it is
not longer necessary to carry out costly
making-up processes.
The many possibilities available for producing the nets will now be presented. An
overview will be given of what warp knitting
technology can achieve in terms of net production. The main processing factors and
the end-uses will also be described. In
addition to information on the actual products, important aspects relating to production and the basic constructions will
also be presented by way of a short introduction.
PRODUCTION OF TEXTILE NETS
5
INTRODUCTION
Nets for the agricultural and
leisure sectors
Olive nets
Shade nets
Harvesting nets
Growing nets
Anti-bird nets
Mosquito nets
Wind-breaks
Anti-hailstone nets
Sun-screens
Privacy screens
Hay-baling nets
Packaging nets
Pallet nets
Circular bale nets
Protecting, safety and
universal nets
Safety nets for buildings
Nets for protecting against rock falls
Catch nets
Container nets
Automotive nets
Sports nets
Goal nets
Tennis nets
Volleyball nets
Table-tennis nets
Catch nets
Nets for dividing-up sporting
facilities
Screens for sporting facilities
Nets for the fishing industry
Fishing-nets
Nets for fish-farms
REVIEW OF THE PRODUCTS
6
INTRODUCTION
BASIC NET CONSTRUCTIONS
The specific characteristics of each net will depend on a number of interdependent
factors:
• the lapping
• the number of guide bars used
• the machine gauge
• the yarn threading arrangement
• the stitch density
• the type of yarn
The following characteristics of the nets can be varied by altering these parameters to
suit the intended end-use::
• the level of shade provided, or sun-protection factor
• the wind permeability
• the opacity
• the stability, or elasticity, in the lengthwise and crosswise directions
Most of the nets produced on single-bar raschel machines are produced by a pillar
stitch-inlay lapping or by other simple basic constructions. The loops in the various
lappings can be processed so that they are open or closed. Some of the most frequently used basic lappings are:
Pillar stitch
A pillar stitch construction is the first choice for producing the nets, and it is the most
frequently used lapping when manufacturing nets. In most cases, the pillar stitch is
responsible for ensuring that the nets have the required lengthwise strength and stability. To produce a textile substrate, the pillar stitch construction must be combined
with an inlay lapping or one of a number of other lappings (Fig. 1).
Inlay (weft)
As with the pillar stitch lapping, the inlay cannot produce a textile substrate on its own.
The inlay is responsible for maintaining the crosswise stability, and can join two, three
or more stitch wales together. As a general rule, the more wales that are joined together in an underlap, the more stable is the fabric (Fig. 2).
Tricot
The basic tricot lapping is produced by sideways shogging of the guide bar in relation
to the adjacent needle. When worked without any additional guide bars, this lapping
produces an elastic fabric. Because of its own high elasticity in the lengthwise and
crosswise directions, the tricot lapping is seldom used for producing nets, unless an
additional guide bar is used (Fig. 3).
2 x 1 lapping
As with the tricot lapping, the 2 x 1 lapping joins together adjacent wales. Unlike the
tricot lapping, the next loop is not produced on the adjacent needle, but on the next
but one needle. The same principle applies to all the other stitch lappings, with the
exception of the pillar stitch construction (Fig. 4).
Combining these lappings produces a wide variety of different fabric characteristics
and two, three or more lappings can be combined. This enables the specific characteristics of a product to be varied extensively.
1
2
3
4
7
PRODUCTION OF THE NET OPENINGS
INTRODUCTION
Net openings having a variety of different sizes and shapes can be produced in a
number of different ways, in which case, the choice of gauge, construction and stitch
density are decisive factors in determining the shape and size of the openings.
Another factor is the yarn threading arrangement into the guide bars. This does not
necessarily have to be identical to the machine gauge. Because of the many possible end-uses, threading arrangements of 1 in, 1 out, 1 in, 2 out, etc., are often used
for these types of products. The advantage for the manufacturer is that a wide range
of products can be produced on one machine, without having to carry out any timeconsuming changeover procedures.
Fig. 1: Fully threaded, Fig. 2: 1 in, 1 out, Fig. 3: 1 in, 2 out
1
2
3
8
INTRODUCTION
In order to improve handling and to join
individual webs of net together, the knitting operative can incorporate different
reinforcing strips and edgings, depending on the machine’s features. These
include eyelet-holes or straps, which
may be located at the edge or in the
middle of the net. They are usually incorporated in the vertical direction, but may
sometimes be worked in the horizontal
direction as well.
The functional zones in the nets can be
varied and produced in a number of different ways. The three main types and
their possibilities will now be described.
Reinforcing strips and
functional zones
Reinforcement and functional zones can
be incorporated at the edge or in the
central zone and, in addition to providing
the net with additional support, also
make it stronger and produce an excellent edge.
The edge of the textile can be reinforced
in a number of ways:
• by using additional guide bars
• by threading several or thicker yarns
in the guide
• by changing the gauge (e.g. main part
E 12, 1 in, 1 out, and the edge, E 12,
fully threaded)
Straps
Straps (draw strings) usually run as zero inlays (filler thread) into the net during the
knitting process, and are fixed in place between the underlaps of the other guide
bars. These straps stabilise the nets once they have been erected, and can also be
used for subsequently incorporating steel wires, cords or similar materials (Fig. 3).
Eyelet holes (buttonholes)
Various lappings can be used to work the eyelet constructions. They can be formed
using loop or inlay lappings and by using one or several guide bars. The length of the
eyelets and the distance between them can be increased or decreased by adjusting
the lapping, and the width of the openings is determined by the threading-in arrangement and the lapping.
These additional possibilities enable the eyelet strips to be designed to suit specific
applications, and the distance between the holes can be adjusted to suit the particular end-use of the net. Nets for covering scaffolding are one example of this type of
net. The eyelet holes in the net are knitted-in so that they correspond to the distance
between the scaffolding supports, which enables the nets to be accurately mounted
and fixed to the supports (Figs. 1 and 2).
INCORPORATION OF FUNCTIONAL ZONES
1 23
9
INTRODUCTION
KNOTLESS NETS
The difference between knotless
and knotted nets
Nets produced on warp knitting machines
are ‘knotless’ constructions. The single- or
double-bar raschel machines used to produce these nets process the yarns directly
from a warp beam to produce the net. In
this case, all the yarns are processed vertically into the connecting sections. The
guide bars are moved to the adjacent connecting section at specific intervals, which
produces the joint or so-called ‘knot’. An
examination of the net shows a textile
having a uniform thickness, without any
bumps in the ‘knot section’. Consequently,
this has given rise to the term, ‘knotless
nets’.
On the other hand, knotted nets are produced by knotting yarns that have already
been twisted together in a specific cycle to
form a net. The connecting sections and
joining points (knots) can be varied,
depending on the size of mesh required.
Any adjustments are made via the lapping.
This knitting technology allows the knitting
operative to easily lengthen or shorten
both the knots and the connecting sections
for the same yarn use. The weight changes slightly when the size of the mesh is
changed.
The width of warp-knitted nets is always
specified along with the number of mesh
openings in the net, since the maximum
span width of the nets will vary according
to the size of the mesh and the relationship
between the knot length and the length of
the connecting sections.
The characteristics of knotless
nets
• a smooth textile surface is produced by
the way in which the loops are joined
together. This results in low energy
expenditure when the net is used for
fishing, since the flow resistance is low
• the size of all the mesh openings is
exactly the same, and the joining points
are completely slip-resistant
• good abrasion resistance, since no
knots protrude from the surface
• no finishes are required, since the
joining points are completely stable
• long production cycles, since the warp
beams have a long running length
• economical, untwisted filament yarns
can be processed
• the knotless construction reduces the
risk of injury to the user during use
• high energy absorption capacity.
mesh
mesh
knots
connection section
10
Photo: Messe Frankfurt
TYPES OF MATERIALS
INTRODUCTION
Every type of raschel machine can process
a wide variety of yarn types and structures.
Synthetic yarns are usually used, including
polyester (PES), polyamide (PA) and polyolefines such as polyethylene (PE) and
polypropylene (PP) in the form of filament
or spun yarns. These yarns can be used in
a wide range of different shapes and constructions, and may be flat, textured, shiny,
matt, circular, structured or spun-dyed.
Less conventional materials, such as
metal wire, reflective or conductive yarns,
tape yarns, natural fibres and every other
conceivable type of material can also be
processed. This applies to all the products
and machines described in this brochure.
Agricultural nets are usually made from
polyolefine in the form of tape or monofilament yarns.
Polyethylene is usually used for the following reasons:
• the yarn parameters (elongation and
strength/stability) can be stipulated in
advance
• low weight
• no water absorption
• flexibility
• high strength
• rot-resistance
• weather-resistance
• can be dyed in any colour.
Depending on the requirements of the end
product, polyethylene may either be processed in the form of tape or monofilament
yarns, but combinations of the two are not
uncommon. The choice of which yarn to
use will depend partly on the characteristics of the end product, and also on the
type of machinery available in the manufacturing plant.
Tape yarns
Nets made exclusively from tape yarns are
intended mainly for use as shade nets.
This is because the tape yarns produce a
flexible, lightweight net having an excellent
sun-protection factor. But this type of tape
yarn construction can also be used in protective nets, such as anti-bird nets.
Monofilament yarns
Nets made from monofilaments are ideal
for use as harvesting or anti-bird nets, but
they are frequently also used as shade
nets.
The nets produced exclusively from monofilament yarns are extremely stable and
durable. However, they need to have a high density if they are to be used as shade
nets, for example. This increases the weight of the net, and the high yarn consumption increases the cost.
Combination of tape and monofilament yarns
A combination of monofilament and tape yarns is suitable for a variety of end-uses,
such as for harvesting nets, anti-bird nets and shade nets.
The textile produced on a double-bar machine is usually made from monofilaments
as the pillar stitches and tape yarns as the inlays. With three-bar constructions,
monofilaments can also be used for the inlays (i.e. monofilaments in the pillar stitches
and monofilaments and tape yarns in the inlays).
This combination of yarns makes the nets more stable and durable than nets made
exclusively from tape yarns. By using tape yarns as the inlay, lightweight nets having
a high shade factor can be produced for a low material consumption.
Sections made from different materials can also be produced next to each other.
Depending on the final end-use, manufacturers may use polyester, polyamide or
polypropylene multifilament yarns to produce universal nets and fishing-nets.
However, every other type of material, as well as combinations of materials and
colours, can also be used.
11
CIRCULAR BALE AND PALLET NETS
Photo: K.-H. Lahrem
APPLICATIONS
These lightweight polyethylene nets can be used for securing circular hay bales
and for stabilising pallets and piles of boxes so that they can be transported safely. Even bales of silage can be secured with a net first to make them more stable.
The lapping used to produce this type of net is a pillar stitch/inlay combination
which was specially developed for this particular application, whereby the large
width of the openings creates a self-adhesive effect on the circular bales. The pillar stitch wales are spaced wide apart from each other, since the machine operates at only one needle per inch (1 needle to 25.4 mm). The standard width of the
nets is approx. 125 cm and the weight is 9-15 g/m2
.
12
APPLICATIONS
Harvesting nets
Harvesting nets are perfect for collecting
fruits which fall off the tree when they are
ripe, or which have to be shaken off the
tree. Olive groves are a typical example of
this. The nets are placed underneath the
trees until the harvesting period is over,
and are used for catching the ripe fruit as it
falls off the tree. This simplifies and
rationalises the harvesting process considerably.
The size of openings in the net can be
varied, depending on the size of the fruit.
The holes are produced by varying the pillar stitch/inlay lapping. Depending on the
end-use and the type of textile, the machine operates with one pillar stitch and one
or more inlay guide bars. The nets are usually made from polyethylene monofilaments.
Anti-bird nets
These nets can be placed over trees and
fields to protect the fruit from being eaten
by birds. The textile is strong yet lightweight and protects the fruit without restricting plant growth.
The nets are usually worked with two
stitch-forming guide bars, and have a basic
construction in which the openings are produced. The size of the diamond-shaped
openings can be increased or decreased
by varying the repeat length of the connecting sections. The use of polyethylene tape
yarns or monofilament yarns makes the
net extremely durable and hard-wearing.
Anti-hailstone nets
Anti-hailstone nets are used to cover
plants and fruit orchards to protect them
from being damaged by hailstones. Covering fields with this type of net protects
the plants from being damaged by hailstones, but does not restrict their growth.
The nets are primarily made from polyethylene monofilaments and are produced
on two- or three-bar machines using a simple pillar stitch/inlay construction. Tricot or
2 x 1 lappings with a pillar stitch can also
be worked to produce other types of antihailstone nets.
Depending on the stitch density and underlap length, nets having varying shade factors or air-permeability values can be produced for use as shade nets, sun-screens
or wind-breaks. The pillar stitches, which
are usually made from polyethylene monofilament or tape yarns, and the inlays,
which usually comprise tape yarns, give
NETS FOR THE AGRICULTURAL AND LEISURE SECTORS
Photo: Arrigoni
13
APPLICATIONS
the net its own special characteristics. The
knitting technology also makes it possible
to process a loop lapping in place of an
inlay lapping, depending on the strength
requirements. Nets for use outdoors can
also be treated so that they are resistant to
UV light. These types of nets can also be
printed and erected at sporting facilities
and used for advertising, for example.
Shade nets
Shade nets are used extensively in warmer countries of the world. They can be
erected over hothouses and crops to protect the seedlings and plants from the
effects of strong sunlight and to prevent
them from drying out. They can thus be
used to create optimum growth conditions
for the plants. A constant level of air circulation can also be maintained in greenhouses covered with warp-knitted shade nets,
which prevents excess heat from building
up.
Sun protection nets
Warp-knitted nets are not only used in hot
countries for protecting plants, they can
also be used in a range of other, everyday
uses. For example, they can be placed
over play areas, car parks, patios and terraces to protect people from harmful UV
rays and heat. Their low weight makes it
easy for them to be erected easily over
banks of seats and play areas, and they
can be removed just as easily afterwards.
They are a cheap and flexible alternative to
traditional, static sun-screens.
Wind protection/wind-breaks
Wind-breaks are used to protect fields of
young plants, trees or the harvest from
being damaged by the wind. Erecting
wind-breaks protects the young seedlings
and the mature plants from drying out and
being broken. The nets used here reduce
the effects of high winds and help to keep
out airborne sand and salt in areas close to
the sea. Protecting plants from high winds
also encourages plant growth and reduces
the number of irrigation cycles required.
Photo: Arrigoni
14
FISHING-NETS
APPLICATIONS
Knotless fishing-nets are nearly always produced using the same lapping principle.
Here too, the repeat consists of two zones, a ‘knot’ and a ‘connecting section’. The
size of these two zones in the net can also be changed, i.e. it can be increased.
Standard and super knots
With fishing-nets, the distinction is usually made between standard and super-knotted types. Standard knots are usually used in normal applications whereas, with
super knots, two of the inlay guide bars form an additional loop at the joining point
(knot), which increases the volume and strength of the ‘knots’.
Single and double connecting sections
As with the knot, the design of the connecting section can also be varied. With fishing-nets, this generally consists of a pillar stitch wale. If the connecting section
needs to be stronger or have a flat cross-section, the connecting section can be worked with two wales to produce a so-called ‘double connecting section’.
The yarns
Flat, untwisted polyester or polyamide multifilament yarns are usually used.
15
APPLICATIONS
SPORTS AND SAFETY NETS
These universal nets can be used in
every possible end-use. For example,
they can be used to protect people as
well as to secure loads in motor vehicles
and containers. Their main use is for
safety/protection and in the sports sector.
Safety nets are usually used for protecting people. When erected on building
sites, they protect workers in the event of
a fall, and prevent passers-by from being
hit by falling objects.
Like safety nets, sports nets are used to
protect people around sports stadiums
from being hit by flying objects. They can
also be used as goal and volleyball nets,
and as dividing and retaining nets in
sports halls.
Depending on the specific end-use,
these nets must be able to meet certain
protection requirements. The knotless
nets used in these applications are slipresistant and, as well as being extremely strong, also have a high energy-absorbing capacity.
The nets are usually produced on double-bar raschel machines and have two
identical sides. The machine produces
stitch wales on the front and rear needle
bars simultaneously, with an almost circular cross-section, which also reinforce
several inlay yarns. As with all the other
nets, the size of mesh can be varied.
The different shapes of the openings
depend on the ratio between the length
of the connecting section to the knot,
and these give the net its own particular
characteristics. Depending on the construction and end-use, the mesh may
have a hexagonal, a square or a diamond shape.
Photo: www.photocase.com
Kettenwirk-Praxis 2/2005
Several raschel machines, which operate
using different knitting techniques, can be
used for producing the nets. We would
like to describe two of these techniques
in this brochure:
• single-bar raschel machines
(single-face raschel machines)
• double-bar raschel machines
(double-face raschel machines)
Single-bar raschel machines
Agricultural, safety and fishing-nets can be
produced using this technology. The loop
heads (Fig. 1) can be seen on the front of
the textile and the underlaps can be seen
on the reverse side (Fig. 2).
The RS 4 N-F
is an all-round, four-bar machine, which is
used for producing agricultural, protective,
shade nets, etc.
Widths: 170\" (432 cm) and 260\" (660 cm)
Gauges: E 6 and E 12
underlap side
MACHINES SURVEY
WARP KNITTING MACHINES FOR PRODUCING NETS
1
2
loop-head side
16
17
MACHINES SURVEY
Double-bar raschel machines
Double-bar raschel machines produce knotless nets having an almost circular crosssection. Sports and safety nets are examples of this type of net.
Unlike single-bar machines, double-bar machines form loops on both needle bars.
The articles produced in this way are instantly recognisable, since they have two
identical sides on which the loop heads can be seen. In each case, the underlaps lie
between the front and the rear loop head. The nets produced on these machines
have a higher volume than that of those produced on single-bar machines.
However, there is an exception to this rule. Single-bar textiles can be produced on
certain double-bar machines - with double the fabric width. This is based on the principle of a textile web being produced on each needle bar. During the knitting process,
an additional pattern bar joins the two textile webs together on one side. This principle can also be used to produce two separate textile webs simultaneously.
The HDR 8
is a double-bar raschel machine for producing nets having a circular cross-section, such as safety, universal and sports
nets. This machine operates with eight
guide bars.
Width: 130\" (330 cm)
Gauges: E 8 and E 9
The RDS 7
is a double-bar raschel machine, which
produces single-bar shade nets with
double the fabric width.
Width: 193\" (490 cm)
Gauge: E 6
18
YARN FEEDING
Various systems are available for feeding
the tape yarns, monofilaments or filament
yarns to the machine’s knitting elements to
produce the nets. Every system involves
feeding the yarns to the knitting point via
yarn combs and tensioners. Depending on
the lapping, the guide bars knit the yarns
supplied from the various guide bars to
produce different textile products.
The distinction can be made between the
following feed systems:
• an FTL unit
• a frame carrying sectional warp beams
• a combination of a sectional warp beam
frame and an FTL unit
• feed units with beam let-off frames
• feed units with a creel
The yarn may be supplied in the form of a
roll of film, on packages or on sectional
warp beams, in which case the appropriate feed system must be used, or else further processes must be carried out to prepare the yarn.
FTL aggregate
frame carrying the sectional warp beams
✂ ✂
Operating with sectional warp beams
Wound packages (tape or monofilament yarns) are a basic prerequisite for processing sectional warp beams. These can either be produced by companies in-house or else bought-in from outside suppliers. To produce the sectional warp beams, the wound material has
to be processed onto sectional warp beams on a warping machine. The sectional warp beams are then mounted onto a frame, which
is placed over the machine. The yarn is fed directly from the sectional warp beams via tensioning bars and combs to the knitting point.
The number of beam mountings on the frame usually depends on the number of (ground) guide bars. Each beam station can carry
several sectional warp beams, depending on the width of the machine, the number of yarns or monofilaments required, and the size of
the sectional warp beams.
Operating with sectional warp beams and an FTL unit
Combining a frame with an FTL unit enables an article containing tape yarns as well as monofilament yarns to be produced. The tape
yarns are fed from the FTL unit and the monofilaments are fed from the frame.
Operating with the FTL unit
The FTL unit is usually located behind the
machine and is used for feeding the exact
amount of tape yarns required to the
machine.
The film is unwound from the roll of film
and slit into predetermined widths. The cut
tapes are then fed to a stretching zone,
where they are stretched monoaxially, and
the exact amount required is fed to the
raschel machine.
The FTL system is based on a modular
design, and can be supplied as a single
unit or as twin or triple versions. Working
out how many units are needed will
depend on the width of the machine, the
number of guide bars, the machine gauge,
and the final width of the tape yarns.
YARN FEED SYSTEMS
19
YARN FEEDING
Lieferwerke = feed units
Operating with feed units and a
creel
Using a creel is always recommended if
the yarn is wound on packages. The pakkages are mounted in the creel and the
exact amount required is fed via feed units
to the machine.
A variety of creels having different types of
package mountings are available. The size
of the creel and the number of package
positions will depend on the number of
yarns required.
The feed units are used to take-off the
yarns from the creel and feed the tape
yarns or monofilaments to the knitting point
at the correct tension. The number of feed
units used will depend on the number of
guide bars. Each feed position is driven
separately by means of a geared motor.
This process is extremely efficient, since
the packages can be used directly.
However, the fact that a creel takes up a
great deal of space must also be taken into
account.
Operating with feed units and
beam let-off frames
If the aim is to achieve longer running
times by using larger beams, the alternative is to position the beams on separate letoff frames rather than on a frame above
the machine. The beams that are mounted
on let-off frames are larger than standard
sectional warp beams.
They are arranged either in front of or
behind the machine. In this case, the yarns
are fed to the knitting machine via feed
units.
The feed units are used to take-off the
yarns from the beam let-off frames and to
feed the tape yarns or monofilaments to
the knitting point at the correct tension.
The number of feed units used will depend
on the number of guide bars. Each feed
position is driven separately by means of a
geared motor.
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WE 208/1/7/2005/2/5/06 WE 394/01/01/07