Karl Mayer’s Italian subsidiary, Karl Mayer Rotal, involved in the manufacturing of machinery for the textile industries including parts, attachments, and accessories, is making a name for itself with the new Prodye-R, an indigo dyeing machine for stylish denim production of brand manufacturers, and a huge project in the rope dyeing sector.

The Prodye-R indigo dyeing machine can deliver all these benefits and can also be used in the genuine/standard segment. The Prodye-R increases efficiency and reduces costs in rope dyeing. The indigo rope dyeing machine operates with just eight dyeing units to produce deep, pure shades with a dye application of up to 5.5 per cent of the yarn weight. The short wet zone reduces the bath volume by up to 25 per cent. Furthermore, when changing the ball, the warp length remaining in the machine, which is unusable, can be reduced by 20 per cent. Overall, the machine uses less energy and water and fewer chemicals. In fact, the water consumption can be reduced by roughly 30 per cent. The programmable cans, into which the dyed ropes are laid in a precise arrangement, also make the long chain beaming process more efficient.

The Prodye-R complements Karl Mayer Rotal’s product portfolio. With the new dyeing machine, the Ball Warper, The Long Chain Beamer, and the Prosize, the company is the only global manufacturer involved in the one-stop provision of highly innovative rope dyeing technology. One of the biggest companies involved in making-up denim clothing in Turkey, the Taypa Group, is cooperating with Karl Mayer Rotal on a huge project in Algeria. A textile complex for producing textiles and apparel is to be built on an area of 250 hectares in this North African country, which will create 25,000 new jobs. The planned annual output is 60 mn mtr. of fabric per year.

In December 2013, Taypa set up a joint venture with two state-run Algerian textile companies to implement these ambitious plans. In the first stage of this project in the province of Relizane, eleven integrated factories, mainly for producing jeans and other apparel fabrics, will be set up by the spring of 2018. Karl Mayer Rotal will supply the warp preparation technology for producing the denim. The first large shipment left for Algeria in the middle of May 2017.