Getzner Textil has become one of the first companies to test the CASCADE steam recovery system, integrated into KARL MAYER’s PROSIZE sizing machine, in real production conditions. The company measured the system’s energy savings and evaluated the results. Throughout the test phase, Karl-Heinz Vaaßen, Head of Textile Drying at KARL MAYER, provided technical support to Getzner Textil’s production team.
Small steps contribute significantly to company strategy
Werner Egger, Head of Weaving at Getzner Textil, stated that although the savings may appear small at first glance, they accumulate into a meaningful gain over time. Egger emphasized that considering the PROSIZE machine’s operating life of up to 20 years, the cost advantages of the CASCADE system become even more significant. He added that the system aligns with the company’s strategy to reduce manufacturing costs and that CASCADE has become one of the key elements in this process. The system also provides advantages during energy-efficiency audits.
Energy savings also reduce environmental impact
Egger noted that the carbon footprint associated with energy consumption has become an important market criterion, especially in Europe. He shared that optimizing the compressed air system in the weaving department saved approximately 1 GWh of electrical energy, while 11.3 GWh of waste heat is fed into a district heating network used to heat nearby schools. The company’s photovoltaic system also generates around 1.1 million kWh annually.
Early adoption of new technologies creates competitive advantage
Getzner Textil decided to adopt the CASCADE solution even though it had not yet been widely tested in practice. Thanks to the company’s openness to innovation, it had already contributed actively to the development of PROSIZE. During the creation of the new sizing box with a completely redesigned application system, the company worked closely with KARL MAYER Rotal in Italy and provided technological input throughout the process. Previous collaborations also yielded successful results, such as the MULTITENS yarn tensioning system. Initial tests of MULTITENS showed a 2% increase in weaving efficiency and an additional 100 RPM in operating speed.
Long-term technical partnership with KARL MAYER
Getzner Textil relies entirely on KARL MAYER machines for its warping, sizing, and beaming operations. The company also fulfilled Getzner Textil’s request for a small sizing kitchen required for special chemicals used in technical textiles. This long-term collaboration continues due to KARL MAYER’s ability to respond precisely and quickly to customer requirements.
