Rohleder GmbH develops and manufactures furniture and decorative fabrics in Konradsreuth, covering every stage of production from warp preparation through weaving to finishing. The installation of a Multi-Matic warp-sampling machine from Karl Mayer has reduced warp preparation times at Rohleder and expanded the range of design options.
At Rohleder, around 70 weaving machines process a wide range of yarn types and patterns, including complex designs and small to medium-sized production runs, with Karl Mayer’s warp-knitting machines at the heart of the operation. To boost productivity and meet the demands of its growing design portfolio, Rohleder installed a Multi-Matic 128, which replaced three older machines. The machine is designed for the production of sample and production warp yarns up to 400 m in length and features up to 128 individually controlled yarn guides, as well as a working width of 3,600 mm. According to an analysis of production data cited by Rohleder, the Multi-Matic reduces monthly warping time by around 50 per cent compared with the previous system, with the savings increasing as the proportion and complexity of the sample warp yarns rise. Furthermore, the system has made it possible to produce patterns that were previously not economically viable. Sources of error are reduced, as labour-intensive manual steps such as frequent winding and knotting are largely eliminated. “With the Multi-Matic, we save 50 to 60 per cent in warping time per month compared with our previous solution,” comments Peter Rödter, Technical Manager at Rohleder.
From a technical perspective, the Multi-Matic combines state-of-the-art drive control with fully automatic, uninterrupted separation of the warping and sizing processes, automatic colour change with precise yarn laying, and production speeds of up to 800 m/min with minimal yarn consumption. High precision throughout the entire warping process and the interactive determination of the optimum bobbin arrangement ensure consistent warp beam quality. Rohleder is planning further optimisation measures in collaboration with Karl Mayer at the Textile Innovation Centre in Obertshausen.
Rohleder GmbH
Rohleder is regarded as one of Europe’s most modern, internationally active high-tech manufacturers. Since its foundation in 1946, Rohleder has been developing and manufacturing premium fabrics for renowned companies in the global furniture and textile industries. The company has been managed by Christoph Häußler, Matthias Hanitzsch and Leni Rohleder since 2023.
