Highsun, one of the world’s largest company groups specialising in the polymerisation and spinning of polyamide and in the production of spandex, has been using Karl Mayer’s yarn warping machines to satisfy the demand for its products for years. An early subsidiary of the company, the GuiFuRen Company, began warping spandex in 1994 using one of the first elastane warping machines supplied by Karl Mayer.

In the years that followed, Highsun continuously expanded its R&D operations and improved its product quality. With its high-end, innovative products, Highsun won many customers and set up a number of long-lasting partnerships. In 2011, Highsun invested in a large number of Karl Mayer’s warping machines for processing warp beams with elastane yarns and set up its own warp knitting and warping department.

Twenty of Karl Mayer’s elastane warping machines, types DSE HH and DSE 21/21 EC, are currently running in Highsun’s factories. Yarns having counts of from 18 to 640 den can be processed on these warp preparation machines, and beams carrying between 30 and 1,090 warp yarns can be warped. The company also invested in a number of DS 50/32 DNC direct warping machines at the end of 2017 to enable it to produce super-sized beams.

With its flexible and modern warping operations, Highsun can meet the needs of its customers most effectively. Deliveries within the area can be made in less than 24 hours after the order has been placed. Carvico, a well-known warp knitting specialist has been working with Highsun since 2017. The spandex beams are exported directly to Carvico’s factory in Italy and fully meet the stringent requirements of the company’s own quality assurance specifications.

Benefiting the customer

This Chinese company intends to continue cooperating with Karl Mayer. “Highsun will strengthen and consolidate its strategic cooperation with Karl Mayer in the future. Our company group will continue to concentrate on the production of and research into top-quality polyamide and spandex, as well as high-end products to put us at the forefront of healthy development within the sector,” says Mei Zhen, the General Manager of Highsun Synthetic Fiber Technologies, one of the companies in the Highsun Group.

As part of this partnership, Highsun employees and their warp knitting customers can attend courses held by the Karl Mayer Academy China. During these training courses, instructors and service specialists at Karl Mayer (China) provide the customers of both companies with useful information on setting up, operating and maintaining warp knitting machines.

Warping elastane on Karl Mayer’s DSE machines

The DSE HH and the DSE 21/21 EC produce warp beams from elastane and deliver an exceptional level of performance, according to the company. Their vertical process management system enables very fine yarns to be processed gently, the freely running yarn permits the machines to be operated easily, and the machines are extremely flexible in terms of the stretching conditions.

Stretching of the warp yarns on the beam can be selected from between 15 and 100% and is adjusted in three stretching zones. A camera monitoring system interrupts the machine operation in the event of any yarn breakages. If the machine is stopped at full speed, a sophisticated system for synchronising the brakes guarantees reliable control of the yarn sheet.

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