Absolute quality finishing assured for
polyester warp knits with Monforts Montex 6500
New German company GtA is running 24 hours a day to meet digital
printing demand with purpose-ordered Monforts Montex 6500
A new standard in pure white, 100% clean and fault-free
textile substrates is being demanded by the rapid growth in
digitally-printed banners and hoardings – often referred to as
In response to this demand, a new company, GtA (Gesellschaft
für textile Ausrüstung) has been formed and has erected a
purpose-built plant on a greenfield site in Neresheim, Germany.
The plant has been equipped with a fully-automated 72 metre
long installation comprising a washing machine integrated with a
3.6 metre wide Monforts Montex 6500 stenter.
The seven-chamber Montex stenter – purpose-built in Austrian
Monforts production facility “MONTEX Ges. m.b.H.” – is equipped
with a horizontal chain, a padder and an integrated weft
GtA is being run by a seasoned team of textile professionals
led by Managing Director Andreas Niess, with the backing of
Georg and Otto Friedrich – one of the largest manufacturers of
warp knitted textiles in Europe.
With two production plants in Germany and headquartered at
Gross-Zimmern, close to Frankfurt, Georg and Otto Friedrich has
a monthly production of more than 450 t of warp knits – the
equivalent of around six million metres – for a range of end-use
applications, including garments, automotive interiors and
technical textiles, in addition to digital printing substrates.
It is for digital printing, however, in addition to certain
interior fabrics, which are washed and treated at the Neresheim
plant, that GtA has been established.
Andrew Niess, Managing Director; Zeki Yagizi, Production
and Quality Control Manager.
“I have worked with other stenter manufacturers in the past,
but we opted for Monforts technology and the company’s excellent
service we have received’ says Andreas Niess.
Zeki Yagiz, Production and Quality Control Manager agrees.
“We are fully in control of all production and quality
parameters with this line,” he says.
The substrates of choice for digital printing are 100%
polyester warp knits which have extremely smooth surfaces. This
is becoming increasingly critical due to the general move away
from PVC coatings which were the standard in the past.
In addition, they are resilient and allow excellent take-up
of inks, and vibrant colours and clear and precise images to be
achieved with digital printing techniques. The knitted
construction also has the advantage of elasticity, which is a
plus in terms of flexibility for installers.
The raw fabrics to be finished are supplied by Georg and Otto
Friedrich to GtA in weights of 50-350 gsm in rolls of up to 600
kg or 1800 metres. Depending on the fabric weight, GtA is
running the stenter at speeds of between 20-50 metres an hour at
an average temperature of 200ºC.
The entire finishing line is controlled by an EVA quality
inspection and control system which analyses every square metre
of fabric to ensure completely uniform and blemish-free
Another distinctive feature of the line is the proprietary
addition to the Monforts air-to-air heat recovery system which
is now standard with Montex stenters. The GtA line is also
configured for air-to-water heating to save considerable energy
in washing operations.
The complete demand for hot water is generated by the heat
exchanger, which also ensures surplus water for heating the
building and the roof.
In addition, GtA has purpose-designed the automatic chemical
mixing and dosing system that feeds to the padder for the seven
key treatments that are carried out on the fabrics through the
“Here too, we have an extraordinary precise quality control
and usability,” explains Andreas Niess. “Our daily philosophy is
zero mistakes enforced throughout the company.”
Also fully automatic, are the roll inspection tables after
the winder and a robotised cutting and packaging system which
converts the master rolls down to 75,100, 200 or 300 metre
packages to be despatched back to Georg and Otto Friedrich and
its many distributors and partners ready to be printed.
The finished rolls are automatically glued with RFID labels
and embedded in to the company’s own system.
GtA started production in February 2016 and for the first
five months ran a single eight-hour shift. In July last year
this was increased to two eight-hour shifts daily and since
January this year, the company has been operating a three-shift
system 24 hours a day – such is the need for its fabrics.
One of the biggest projects the company has been involved
with Georg and Otto Friedrich to date was the supply of around
14,000 metres of digitally-printed materials for the flags and
banners of the Olympic Games in Rio Janeiro.