340 yarns are taken up on the beam, which is then installed on the Mayer machine to make the ground. Each yarn is placed in a parallel position, with the same tension and at a constant speed.
About 15,000m will be taken up individually at one high-speed rotation. Strict quality control is performed while regulating the thread tension with a computer to avoid problems in the next process, which is knitting.
The Mayer blanket is knitted using Karl Mayer machines made in Germany. The pile yarn is set on the pile-stand and the beam is set on the knitting machine. Then, the fabric is knitted in such a way that the pile yarn crosses between the grounds (to learn more about the ground >> jump to Why we use polyester for the ground ). We can produce blankets of various materials by changing the pile yarn into acrylic, cotton, wool, etc.
This ground is similar to lace. The Mayer knitting machine was originally developed in Germany as a machine for lace, and it was then independently modified in Japan to create the Mayer blanket. Moreover , we can freely change the pile height, although woven blankets can only have very short pile.
We also manufacture towels, which are produced not by using a towel loom but a knitting machine called FBZ. In towel looms, the loop pile can be easily pulled out, which is a disadvantage . However, our towels have a loop pile tied with the ground, just like our Mayer blankets, so it is not easy to pull the pile out. It is also possible to freely set the length of the loop pile, to some extent.
We cut the knitted fabric in half. The fabric enters from the bottom towards the blade, which is always rotating in a circle. In order to cut up to 1000 threads at once, we always need a sharp blade. Therefore, the blade grinds on a grindstone continuously while cutting, which keeps it in a sharp state.