Special Machines and Plants
Automated Processing of Technical Textiles

News

KSL Laboratory18.02.2016

In 2015 PFAFF Industriesysteme und Maschinen GmbH and KSL Keilmann Sondermaschinenbau GmbH were merged. Business is done under the name of PFAFF Industriesysteme und Maschinen GmbH which combines the brands PFAFF INDUSTRIAL and KSL under one roof. In late 2015 the laboratory was established at KSL in Lorsch – a center of excellence that is unique in the industry. The ksl laboratory serves as the interface between complex customer inquiries and sophisticated robot and CNC-technologies. Based on many years of experience and expertise, customer-oriented solutions and concepts are developed at the ksl laboratory. Feasibility studies are carried out, prototypes and small batches are realized and special sewing heads for systems are designed and assembled. In addition, new developments are completed and various KSL-machines and components are tested and optimized. The LABORATORY-concept significantly enhances the vital areas of pre and after sales. Experienced technicians and engineers from IT, sewing technology CNC- and control engineering form the backbone of this new section. Currently, project machines for renowned customers from Europe, the US and Asia are produced at the LABORATORY and implemented in their production lines based on the customer requirements.The Laboratory covers the following technologies:- Blind stitch- Two-needle sewing heads- Tufting- Induction welding- Tape laying- Z-pinning- Ultrasonic cutting- 2D/3D CNC-sewing Larger systems such as a portal sewing robot or a CNC-system that is 30 m long are assembled at the PFAFF INDUSTRIAL-facility in Kaiserslautern, since a bigger assembly area is available there. The subsequent area of application of both systems is fastening (along the Z-axis) large parts for the aircraft and space industries. The portal sewing robot works with a 1-thread chain stitch and is particularly suitable for three-dimensional parts; the CNC-system uses lockstitch to attach two-dimensional components (carbon fiber- and glass fiber).

Techtextil/Texprocess 2015 - New exhibitor and visitor records (Kopie 1)08.05.2015

Around 42,000 visitors from 116 countries made their way to Frankfurt am Main to see the world’s biggest spectrum of materials, processes and technologies for the entire textile value chain during the four days of the two leading international trade fairs. Altogether, 1,662 exhibitors from 54 countries presented their new technical textiles, nonwovens and processing technologies for textile and flexible materials. “Not only was there a fantastic atmosphere at the fair and in the sectors, the visitor standard was exceptional and there were more new products to be seen than ever before. Techtextil and Texprocess 2015 have shown themselves to be the undisputed centre for innovation in the field of high-tech fabrics, smart textiles and processing technologies”, said Detlef Braun, Member of the Board of Management of Messe Frankfurt.
At an architectually impressive joint stand covering more than 1,000 sqm in the entire front section of Hall 5.1 Dürkopp Adler AG and PFAFF Industriesysteme und Maschinen GmbH with Beisler and KSL showcased 110 industrial sewing and welding solutions. More than 300 sales partners from around the world used this joint platform to present the multitude of powerful solutions of the Shanggong-group companies to thousands of visitors every day.
PFAFF Industriesysteme und Maschinen GmbH, Zweigniederlassung managed to appeal to and wow visitors of the TEXPROCESS and TECHTEXTIL alike with the products they presented.
A joint innovation by KSL and Dürkopp Adler is a robotic sewing unit which produces shirt cuffs fully automatically in a reproducible top quality for highest demands. In the shirt production special attention is given to the cuff because inaccuracies in stitch pattern and seam course of the topstitching seams can affect the entire impression of quality.

Due to the high degree of manual work previous production processes were time-consuming and fatiguing for the operators. The new sewing unit for topstitching of cuffs works without an operator. The workpiece is transported by a robot. It takes runstitched and ironed cuffs out of a magazine and feeds them into the sewing unit with precisely aligned edges via a camera programming tool. If the optical sensors indicate that a cuff is not positioned accurately, this is corrected automatically. Thanks to a new material clamp technology design changes can be realized easily. Following the principle of a 3 D printer it is possible to create low-priced style sets anywhere in the world. The unit combines the competence of Dürkopp Adler and the handling know-how of KSL and sets new standards in the automated textile manufacture. It shortens production cycles, avoids downtimes and increases the productivity significantly.

KSL showed two further units at the Texprocess:

The multi-needle sewing unit class 950 eco, a joint development of KSL and Dürkopp Adler, will be newly presented. It is used for the cost-effective stitching through light-weight textiles – single cuts or material on reels – with multiple sewing tools in one operation, e.g. in the production of car seats. The needle distance is variable between 6 and 600 mm, the maximum fabric clearance is 1,200 mm. In order to offer greatest possible performance and versatility combined with lowest possible start-up costs the sewing unit has been equipped with a new control of Dürkopp Adler as it is used not only in approved standard machines but also in complex special automated units. Via the machine-to-machine communication system M2M error messages are sent directly to a defined e-mail address or a mobile phone.

Another trade fair highlight was the freely programmable CNC sewing unit class 311 with rotary head for the servo motor-controlled sewing of safety seams, functional seams and decorative seams. Due to the sewing head tangentially aligned in any sewing direction it is possible to realize demanding seams of highest quality level – with up to 2,800 stitches per minute.

The sewing head rotatable by 360° is always tangentially directed while sewing so that loop stitches are avoided. Thanks to the accurate repetition the unit is ideal for serial parts. And it saves time: Already during the sewing operation the next material clamp can be loaded. The overlapping working method minimizes the time needed for changing the workpiece. The compact unit can be extended by a twin-needle version, an automated material clamp feeding system and intelligent material clamps for components with additional attachment parts requiring the opening and closing of individual component holders during the sewing process.

On the company's 50th birthday: The world is invited to KSL11.07.2014

Lorsch/Bensheim. The guests watch as the robotic arm stitched a precise double seam in the soft leather: its movements follow the three-dimensional structure of the dashboard. What is being finished here is the luxury interior of a leading vehicle marque.
Sewing technology that is “made in Lorsch” is high-tech – yet it can look back on a long tradition. Exactly 50 years ago Keilmann was established as a company in Lorsch. Today it is called KSL “Keilmann Sondermaschinenbau Lorsch”. To celebrate the anniversary, the company held an in-house exhibition for trade visitors from 7 to 10 July, which will be followed by a celebration for guests and employees.
KSL is one of the technical leaders in the sector. “We are inventors,” says Managing Director Robert Keilmann: we have a global reputation for innovation in the field of automated sewing technology. The company exports 80 % of its production. It is therefore no surprise that the in-house show will welcome customers and partners from twenty countries – from Europe, Turkey, Tunisia, the USA, India and China.
Our invitation had been accepted by so many guests that there would not have been enough space at our Lorsch site for them and the more than forty machines that were on show. A quick decision was therefore made to convert the second site in Bensheim into an exhibition hall. The company gave live demonstrations of the production processes on many machines – for example, a high-speed manufacturing system for filter pockets, CNC sewing units, welding technology, airbag manufacture, carbon-fibre applications and the latest robot technology. It reflects the customer portfolio of the inventors from southern Hesse: automotive engineering, aerospace, filters, household textiles, fashion and many other industries use KSL technology in their manufacturing processes.
Since 2013 KSL has been part of the ShangGong Group, which also owns many famous names in the field of sewing technology such as Dürkopp Adler and Pfaff. Machines from these two companies will therefore also be on show in Bensheim.The guests were delighted and have found their visit fascinating: they gained an insight into the history of sewing technology, innovations in the processing of technical textiles and a glimpse into the future of automation.

CATMA is new sales representative of KSL in Turkey20.03.2014

As of now ÇATMA TEKSTİL, located in Istanbul, will be the representative for KSL in Turkey. The company, also representing Dürkopp Adler in Turkey, is a highly experienced partner for sales and service and works in a close cooperation with the international sales team of KSL.

Keilmann Group builds special purpose machines for processing of technical textiles and fiber composites. The range of delivery includes CNC- and multi-needle sewing units, robot systems, gluing- and welding units up to automatic manufacture lines. Machines of KSL are put into operation for production of upholstery, filters, Airbags, automotive interiors, mattresses, composite components, fashion and leather goods.

The export quota of the southern German manufacturer of special purpose machines comes up to 80 per cent. Since 2013 KSL belongs to the ShangGong Group which is holder of further global players of the sewing technology like Dürkopp Adler and Pfaff.

Contact:
Çatma Plaza Basın Ekspres Yolu Bahariye Caddesi No:89
İkitelli, İstanbul / TURKEY

Mr. Yavuz Çatma
Phone: +90 212 494 24 44
Fax: +90 212 494 38 28
E-mail: catma@catma.com.tr
Web: www.catma.com.tr

Research meets manufacture: Automated sewing and laying processes with KSL systems13.03.2014

A workshop in Stade. With fast, precise stitches a blind stitch sewing machine joins individual CFK layers on a portal automatically to a large nest. Here sprouts the pressure dome for the Airbus A380. The sewing unit for this task is supplied by KSL,  a Southern German special purpose machine manufacturer.

The Boeing 787 Dreamliner contains KSL sewing technology, too. A robot places CFK-threads for reinforcement into the airplane components by tufting technology. Joining components of a passenger door with seams, the number of required titanium rivets can be reduced and thus reduces weight. KSL was dedicated to this task in a corporate research project for which the project team was rewarded with the JEC Innovation Award.

"Not everything that is produced with our equipment takes off," says Robert Keilmann, managing director of KSL GmbH. "Similar techniques are often used in the automotive industry." Such as the Mercedes-Benz SLR crash elements. Threads are placed - also with the tufting technique – to influence the behavior in a crash. KSL is a manufacturer of sewing systems and automation techniques for the processing of technical textiles. The field of composites is booming, but is also a particular challenge. "Almost everything in the field of composites that is manufactured on our machines, are innovations. Our customers want to bring new technologies into practice quickly and economically. This is possible only in very intensive professional dialogue," says Robert Keilmann, managing director of KSL GmbH.

He is not speaking of customers only. To develop and establish new techniques, KSL also works closely with universities and research institutes. The Southern German company builds portal and robot systems for the processing of composites. The units are used to produce layers, sub-preforms and preforms and to join unidirectional and multi-axial fabrics. KSL units manufacture components made ​​of carbon fiber, glass fibers or aramid, from profiles or stringers up to complex three-dimensional components.

In the laboratory in the Southern German city of Lorsch KSL produces prototypes and small series for customers from all over the world. For planar applications usually CNC sewing units are joining for example CFK material layers. Components with complex three-dimensional geometries require the 3D-sewing technique. KSL equips 3D-robot systems with stitching heads and control systems for special applications such as tufting, blind stitch seams, double-needle stitching.

Depending on the application, the robot can join composites, separate with an ultrasonic cutting head or lay CFK-tapes with a laying head for manufacture of preforms. The KSL portfolio does not only include composite applications.

On KSL units airbags, textile filter technology, home textiles, fashion or safety engineering are manufactured worldwide. This year KSL celebrates its 50st anniversary and is since 2013 a member of the Shang Gong Group together with other global players in the sewing technology such as Dürkopp Adler and Pfaff.

One of the biggest sewing machines in the world comes from Lorsch07.03.2014

The „blue wonder " fills a workshop in Lorsch, consists of about 20,000 parts and weighs 73 tons. The largest sewing and welding machine KL 820 is almost completed, the largest machine ever built by KSL. The special machine manufacturer is a global specialist for innovative sewing technology. A sheet of black material moves through the blue painted steel construction. The machine stitches and welds tracks of geotextiles, which are foil, fabric and fleece, which are processed, for example, for rain retention basins and slope fasteners. Two years ago: in Lorsch a Canadian company and a team of engineers from KSL sit together. The Challenge: 300 meters long and 6 meters wide geotextile tracks shall be fully automatic stitched together into football -field-sized areas. In the following months the KSL engineers worked closely together with the customer. The seemingly impossible comes to solution, the construction can begin. The machine is extremely compact and yet 50 meters long and 10 meters wide. Overall, the machine can produce a contiguous area of 7,500 square meters of textile. The "football field" is wound in zig-zag back onto a roll, which weighs about 5 tons. In order that the finished roll does not slide apart, the track is wound with a tension of 11,000 Nm – if you want to bring such torque to the road, it would take several sports cars.
Even when sewing and welding the machine is a power pack. Four welding machines with an output of 2,600 watts and 4 sewing machines join the geotextile tracks. Several millimeters thick fabrics and foils fit together as a tension-resistant and on request waterproof tarpaulin. The quality monitoring is complete: An integrated monitoring system monitors with its infrared eye, whether the weld seam quality is impeccable. If the thermography shows a deviation, the machine is automatically stopped. Each of the strong polyester threads, which joins the heavy material with up to 3 millimeters thick needles, is monitored. "An unit of such dimensions, which can connect material layers of up to four millimeters fully automatic, is unique in the world," says Robert Keilmann, Managing Director of the Lorscher special machine manufacturer. It is currently in process of acceptance by the customer and by the CSA, the Canadian equivalent of the German TÜV. The machine will then travel in 11 shipping containers to Canada to be reinstalled by 3 KSL technicians. KSL develops equipment for the automated production of technical textiles for many industries: the automotive industry, home textiles, the filter industry, fashion and furniture. The portfolio includes robotic systems for carbon and glass fiber applications in the aerospace industry. The export share of the South German manufacturer of special machines is 80 percent. Since 2013 KSL is a member of Shang Gong Group, to which other global players in the sewing technology belong, such as Duerkopp Adler and Pfaff.

KSL celebrates its 50th anniversary28.02.2014

Sewing is a high topic technology with a long history.
KSL is part of this history since 1964. This year KSL does celebrate 50 years and is one of the most innovative in this branch.

During the founding years “Keilmann Company” sold and repaired sewing machines for the private use. It did not take long to see the opportunities of sewing technology and to start making the machines suitable for industrial standards. Machines for automobile seat covers, airbags and upholstery were made available.

Automation “made by KSL” opened three essential advantages to the industry: reproducible quality, speed and low manufacturing costs.

Automotive remains a main focus until today. Top ranking have applications for home textiles, filter industry, fashion, furniture and – since carbon- and glass fiber emerged – aerospace.

The export quota of the southern German manufacturer of special purpose machines comes up to 80 per cent. Since 2013 KSL belongs to the ShangGong Group which is holder of further global players of the sewing technology like Dürkopp Adler and Pfaff. 

Half floor space requirement – full speed: KL 310 manufactures airbags in one process28.02.2014

Headbags can not be manufactured faster, more efficient and on smaller space . With the KL 310 KSL brings an extremely space-saving sewing unit on the market. The KL 310 manufactures an airbag in one process. And saves manpower - two machines can be operated parallel by one operator only. The fully automatic template changing system does not only save precious time, but also a lot of floor space.
Compared to sewing units from other manufacturers KSL did cut the needed floor space in half. The KL 310 sews with 2800 stitches per minute and is available from March 2014.

KSL introduces KL 205 semi-automatic straight seam sewing unit 27.02.2014

With flying colours it passed its first mission, all seams are perfect.
The newest development of the southern German mechanical engineering expert is named “KL 205”. This semi-automatic sewing unit manufactures seat covers for automobiles for a well-respected Russian manufacturer.  “Extremely efficient with high quality” this is how Guido Jaeger, head of sales at KSL, sums up the advantages. The unit is the perfect choice for companies who want to convince with quality and efficiency.
The KL 205 is especially suitable for straight seams and diamond patterns, virtually for all technical textiles and ideal for the upholstery industry as well.

High-speed and automation for filter manufacturing25.10.2013

Heavily frequented was the stand of the South German special machine builder KSL at the FILTECH 2013, which was held from 22 - 24 October 2013 in Wiesbaden. KSL presented machines and manufacturing systems for the filter production – an industry, in which KSL for decades has built up consolidated know-how. The spectrum of the facilities reaches from sewing through ultrasonic welding to automation technologies.   A highlight of the show was the high speed manufacturing system 300 FPS. It produces up to 36 filter bags per minute at a maximum speed of 20 meters per minute. On KSL ultrasonic welding systems arise filter bags in top space and diamond space method. Sewing machines for filter tubes and filter cloths complement the machine program. Guido Jaeger, sales manager, is very satisfied: "We not only had many, but also many good contacts, interest in automation is very high. The large companies in the filter industry are our guests, many prospective buyers from the USA, Turkey, Russia and Asia. With our equipment high efficiency gains are possible, which makes them very attractive and profitable. "

CISMA Shanghai – KSL shows the future of sewing01.10.2013

Lorsch, October 2013

“Will robot technology replace the conventional sewing technology”? “Is this the future of sewing?“ Questions like these were posed by visitors at the KSL booth during the CISMA in Shanghai. Precise movement and 3-D seam flow of the KL 500 robot sewing unit captured hundreds of visitors. Robert Keilmann, managing director of the southern German company: „Of course do our robot units open new potential, in particular in the field of 3-D. However, they do not replace any technology, but broaden our range of delivery instead. Our range of delivery starts with CNC controlled sewing systems, multi-needle sewing units, gluing- and welding units up to fully automatic production lines. Besides, we do not speak of future, as our technologies are put into operation for some time now for serial production.“. The robot, the magnet at the booth, for example produces dash boards, side panels or arm rests with a high demand on optical appearance for leading automobile manufacturers.

 

Despite the huge booth at the CISMA space became tight. Visitors from apparel industry as well as from the field of technical textiles could get a good picture of flexibility and speed of the units during live-demonstrations, such as airbag manufacture on a KL 110 CNC sewing unit with 360° rotating sewing head. This universal unit does not only sew airbags, but also for example convertible tops or upholstery. The modular designed KL 960 multi-needle sewing unit found great interest as well. Filters, car seats and many others are manufactured on this unit. KSL is manufacturer of innovative sewing systems and automation technologies for processing of technical textiles. Fields of application are airbags, automotive, fiber reinforced composites, textile filter technology, home textiles, mattresses, fashion and safety features and equipment. Since 2013 KSL belongs to ShangGong Group together with Dürkopp Adler and Pfaff as further global players in the field of sewing technology.

Keilmann Group taken over by ShangGong Europe Holding Corp. GmbH13.08.2013

Lorsch, August 2013

ShangGong Europe Holding Corp. GmbH, Bielefeld, has taken over the interests at the organisations of Keilmann-Group from Mr. Robert Keilmann.

Keilmann Group builds special purpose machines for processing of fiber composites and technical textiles. The range of delivery includes CNC- and multi-needle sewing units, robot systems, gluing- and welding units up to automatic manufacture lines. Machines of Keilmann Group are put into operation for production of composite components, filters, airbags, upholstery, mattresses, fashion and leather goods.

ShangGong Europe Holding Corp. GmbH is majority stock holder of Dürkopp Adler Aktiengesellschaft, Bielefeld and sole stock holder of Pfaff Industriesysteme and Maschinen AG, Kaiserslautern. Both organisations are operating worldwide in the field of industrial sewing technique.

Keilmann Group and ShangGong Europe Holding Corp. GmbH do expect positive impulses from this take-over for a mutual future growth.

KSL introduces new multi-needle sewing unit25.02.2013

Lorsch, February 2013

Compact and particularly easy to maintain - that best describes the new multi-needle sewing unit, which KSL Keilmann Sondermaschinenbau GmbH will introduce at the Techtextil 2013 trade fair in Frankfurt. The unit was redesigned from scratch and given a leaner appearance, with the integrated switch cabinet additionally reducing the required space. The operation via touch screen is intuitive. The main application of the KL 960 is the straight continuous sewing of parallel seams, a process that is standard in many industries, for example in the manufacture of car seats, the interior fitting of boats or the manufacture of insulating materials. Thanks to a number of advantages, such as the continuous processing or the undersewing of tapes, the unit can be universally employed. The multi-needle sewing unit KL 960 thus supplements the product portfolio. The predecessor model KL 950 will however continue to be produced, the company advised.

KSL develops robot-supported sewing units for EUROSTARS research project05.02.2013

Lorsch, February 2013

Good progress is made at the technical centre in Lorsch. Two corresponding robots with sewing heads fasten high-quality leather on a support foam and feed it to the next production step. The project will eventually comprise the fully automated manufacture of leather seats for the automotive and aviation industries. It is to replace the previously manual process and will ensure a consistent highest level quality. Car Trim GmbH and KSL Sondermaschinenbau GmbH are closely cooperating in this joint project that is supported by the Federal Ministry for Education and Research. The results will be published shortly.

Eurostars is a support program that is open to all kinds of topics and aimed at small and medium-sized companies (SME) carrying out research and development projects within the scope of the European research initiative EUREKA. The program promotes civil research projects for the development of new products, processes and services. The Car Trim group of companies develops and produces high-quality components for the automotive and aviation industries.

Most successful business year since foundation24.01.2013

Lorsch, January 2013

With an increase in turnover of 35% compared to the previous year, the Keilmann Group has recorded its most successful year since its foundation. "In particular in the areas automotive and filter production, KSL Sondermaschinen GmbH has seen a tremendous growth", says Robert Keilmann, managing director of the company that is based in Lorsch. The largest growth rates the group of companies recorded in the Asian and North American markets. Among the growth factors during the business year 2012 were the trend towards automation that spanned all industries as well as the increased use of sewing technology in the field of fibre composites KSL has specialised in. The Keilmann Group unites the three companies KSL, KSA and KSE under one roof.

2300 m2 new production area in Bensheim21.12.2012

Lorsch, December 2012

Commissioning the new KSL factory II Bensheim has permitted the special machinery manufacturer KSL Keilmann Sondermaschinenbau GmbH to again expand its production capacity. In close proximity to the headquarters in Lorsch, mainly larger installations and continuously automated production lines are assembled. Apart from continuously increasing orders, the trend towards automation and the use of modern robot technology were decisive reasons for the expansion. "Time to market is of ever greater importance, in particular in the automotive industry. The second site makes us more flexible as far as peaks in demand are concerned and improves our delivery capacity", says Robert Keilmann, managing director of KSL.