KARL MAYER will showcase a new composite machine at its Chinese location that is specifically tailored to the needs of the wind power industry.
Its high speed and maximum efficiency make this new machine particularly attractive for growth markets such as China.
specialist in high-performance wind power textiles
With the MULTIPLY BX, KARL MAYER is expanding its composite portfolio to include a machine with a clear focus: the highly efficient production of biaxial non-crimp fabrics for rotor blades. The new machine processes glass fibers with a non course-oriented weft-insertion into reinforcing textiles with a high proportion of filler yarns, light weft yarns, and long stitch lengths – materials that are in extremely high demand for the unidirectional reinforcement of wind turbine blades.
This consistent specialization is paying off: The MULTIPLY BX combines a design focused on wind turbine-specific products with outstanding productivity.
“When developing the MULTIPLY BX, we consistently focused on the needs of our wind power customers. The starting point was a special fibre reinforcement fabric; the result is a highly efficient machine in its field. We look forward to presenting it during our Product Show at KARL MAYER (China) during ITMA ASIA 2026 and to a wide-ranging discussion about it.”
Dr. Jürgen Tröltzsch, Product Specialist for Composite Machines, KARL MAYER Technical Textiles
up to 25% increase in productivity
With production speeds ranging from 1,600 to 2,200 min⁻¹, depending on the stitch length, the MULTIPLY BX achieves an output of up to 500 m/h. This makes it 20 to 25% more productive than the MAX GLASS ECO, which has also established itself in the wind power market.
The machine reaches its full performance potential at large stitch lengths of 4 to 5 mm, which are typical for products established in this market. The combination of filler threads with a yarn count of up to 2,400 tex and light weft yarns ranging from 100 to 200 tex for transverse stabilization serves to prioritize fiber reinforcement in the longitudinal direction. The weight ratio of filler to weft yarns in the finished fabric is typically 6:1.
proven technology plus targeted enhancements
The high efficiency of the MULTIPLY BX is based on a well-thought-out design that combines proven solutions with targeted technical enhancements. The operating concept, selected technological components, and the basic structure of the laying system were adopted from the MAX GLASS ECO.
The changes primarily affected the weft insertion width and the warp knitting area.
To increase output, the width of the weft carriage was expanded from 8“ on the MAX GLASS ECO to 12” for parallel weft-insertion and to 16″ for cross weft-insertion.
In the warp knitting zone, an adjusted needle lift movement reduces the formation of so-called “fish eyes,” which occur when the knitting needles pierce the laid fabric. The fish eyes reduce as hole-shaped quality defects the mechanical performance of the fiber-reinforced semi-finished products.
In addition, the lever movement has been optimized to minimize vibration during high-speed operation. The result: smooth machine operation, less wear, and a comfortable working environment for operators.
Greater Working Width for Optimal Material Utilization
The MULTIPLY BX is also consistently designed to meet the requirements of rotor blade manufacturers when it comes to working width. The increase from 101 to 103” enables better material utilization in the production of narrow strips, into which the wind turbine textiles are cut for further processing.
As a result, the MULTIPLY BX combines high production output with material efficiency tailored to the specific application – positioning itself as a specialized solution for the cost-effective production of high-performance reinforcement textiles for rotor blades.