A growing consciousness to become fit and healthy is fueling the growth of the activewear textile market in India. A.T.E. provides the entire range of activewear manufacturing solutions covering warp knitting and processing from leading manufacturers around the world including KARL MAYER, Fong's, Goller, Monforts, Then, Zimmer, ColorService, Mahlo, and more. Click on the link to find out more.

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A.T.E. Enterprises Private Limited
V2.1 Mar 2018
Activewear
Warp Knitting and Processing Solutions
from A.T.E.

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 Athleisure wear or Activewear is
defined as “casual, comfortable
clothing suitable for sport or exercise”
 Clothing designed as a transition
from leisure to casual daytime or
evening wear
 A style of clothing that is comfortable
and suitable for doing sports, but also
fashionable and attractive enough to
wear for other activities
Ath(letics) + Leisure = Athleisure
Source: https://www.dictionary.com/browse/athleisure
Source: https://dictionary.cambridge.org/dictionary/english/athleisure
Source: Book- Latest Material & Technological Developments for Activewear
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About activewear
 Enhances the performance of athletes during sports or
fitness physical activities by aiding in body movement
 Useful in preventing muscle sprains and other ligament
and muscle-related injuries
 Unique advantages of breathability, quick drying, static
resistance, thermal resistance and chemical resistance
boost their adoption among consumers, thereby
propelling the market growth
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Characteristics
 Protection
 Insulation
 Air permeability
 Stretch
 Shape retention
 Optimum heat and
moisture regulation
 Rapid drying
 Dimensionally stable in wet conditions
 Durable
 Easy care
 Light weight and soft touch
Source: Cottoninc.com

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Applications of active wear
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Typical sports-specific garments
Dry
 Shorts
 Track suits
 Track/field t-shirts
 Polo shirts
 Leotards
 Training wear
 Outer jackets
 Tights or leggings
 Yoga pants/leotard
Wet
 Swim wear
 Dive wear
 Surf wear
Moist
 Ski wear
 Skating wear
 Snow jackets
Inner sports wear
 Jockstrap
 Sports bra

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Global activewear market
Source: https://www.alliedmarketresearch.com/activewear-market

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Global activewear market
Source: https://www.alliedmarketresearch.com/activewear-market

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By product type:
• Outerwear (pants, t-shirts)
• Footwear
• Underclothing
• Hosiery
• Accessories
Activewear market
By fabric type:
 Polyester
 Nylon
 Neoprene
 Polypropylene
 Spandex
 Cotton
 Others (Rayon and lyocell)
Demand for polyester by fabric is increasing, owing
to extensive advantages of this fabric such as easy
drying, adequate stretchability, easy wash,
resistance to abrasion and shrinkage, wrinkles
resistance, and chemical resistance
Source: https://www.alliedmarketresearch.com/activewear-market 7

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 Adidas AG
 Asics Corporation
 Columbia Sportswear Co.
 Dick's Sporting Goods Inc.
 Nike Inc.
 Puma SE
 Decathlon S.A.
 Skechers U.S.A., Inc.
 Under Armour Inc.
 Alcis Sports
 Proline India Ltd.
 Fila
Major players in the activewear market
Source: https://www.alliedmarketresearch.com/activewear-market

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India’s activewear market
 India is rapidly converting into a sports- and fitness-conscious country
 Aerobics, swimming, running, yoga, various dances have now become a part of life
 In India, the activewear segment is witnessing a growth rate of 18-20% annually and
expected to touch around USD 8 billion by 2020
 International brands are heavily investing in experiential and omni-channel marketing
 Key products include track pants, shorts, leggings, hoodies, t-shirts, sneakers and
power leggings
 Users find athleisure wear a refreshing change from formal shirts and casual denims.
People wear athleisure not only while working out, but also at work
Source: https://www.indiaretailing.com/2019/07/31/fashion/athleisure-riding-high-on-innovation-and-trends/
Source: https://www.indiaretailing.com/2019/10/29/fashion/decoding-the-athleisure-revolution-in-india/
Source: https://bestmediainfo.com/2019/09/why-athleisure-wear-is-outpacing-the-rest-of-apparel-categories/
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Growth drivers
Source: https://www.alliedmarketresearch.com/activewear-market 10
Growing
wealth
Changing
lifestyle
Rising
urbanisation
Young
population
Increased
health
conscious
-ness
Advancements in
manufacturing
technologies
i.e. waterproof, anti-microbial,
antiviral and breathable
textiles
Sports
taken up as
a
profession

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Activewear
Warp Knitting Solutions
from A.T.E.

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Knitting – an important fabric forming process
Warp knitting for activewear
Circular knitting
Yarn supply from bobbins
Warp knitting
Yarn supply mainly from beams

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 Most versatile fabric production system in textiles
 Can produce various structures:
 Rigid/elastic
 Open/closed
 Flat/tubular/3 dimensional
 Fabric width can go up to 7 meters (without seams) and even multiple of this width
in net construction
 Warp knitting techniques are still unknown to many textile consumers
 It is often mistaken as woven or circular knitted fabric
Warp knitting for activewear
Woven structure Warp knitted Circular knitted

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Warp knitting process flow chart
Yarn package
mounted on creel
Warping of beams
on direct warping
machine
Fabric forming on
warp knitting
machine
 Beams (SEMYUNG Korea)
 Warping machine & creel
(KARL MAYER India)
 Warp knitting machines
(KARL MAYER, Germany)

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Warp knitted activewear
Properties of warp knitted fabrics suitable for activewear:
- Dimensional stability - Higher ductility
- Better length wise stretch - Stronger stretch (4 ways)
- Less transparency - Lower shrinkage rate
- Less curling - Stronger mesh, tulle and net structure

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KARL MAYER offers solutions for producing the most suitable fabric for use in high-
end, stylish, hardwearing, warp-knitted swimwear for the beach, the pool and
competitive swimming
Swimwear
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KARL MAYER also offers a range of machines for developing innovative, high-
performance shoe fabrics. Single face tricot fabrics, patterned spacer textiles, to
engineered jacquard fabrics and even lace
Sports shoes
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Sportswear
KARL MAYER’s machines add functional characteristics to sportswear as well as
create special optical effects
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Composite textiles for sports gear
KARL MAYER’s offers machines for the manufacture of innovative, high performance
light weight textiles like sports helmets made up of high performance fibres like glass
carbon or aramid
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KARL MAYER solutions for activewear
Tricot Rascheltronic®
Double needle bar Seamless
 Shoes
 Swimwear
 Sportswear
 Outerwear
 Sportswear
 Swimwear
 Outerwear
 Shoes
 Sports jacket
 Thermal mats
 Protective clothing
 Seamless
 Sportswear

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 Is an innovative market leader for solutions in warp knitting,
warp preparation for weaving and technical textiles
 German family-owned company, founded in 1937
 More than 2,400 employees worldwide
 Manufacturing facilities in Germany, Switzerland, Italy,
Japan, China and India
 KARL MAYER is one of A.T.E.’s oldest partners with a
relationship of more than 6 decades
 Today the famous names of Sucker, Benninger, Griffin,
Rotal and Stoll are all part of KARL MAYER
About KARL MAYER
WARP KNITTING
TECHNICAL TEXTILES
WARP PREPARATION

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Applications – warp knitting
Apparel
Sportswear
Home
textiles
Semi-technical
Nets
Automotive textiles

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Activewear
Processing Solutions
from A.T.E.

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 P/C blended
 100% polyester
 100% nylon
 100% polyester with 10-30% Spandex
 Width - 42” to 84”
 Minimum GSM - 90
 Maximum GSM - 350
 Circular knitted fabrics
 Warp knitted fabrics
 Woven fabrics
Types of substrates and composition

25. 25Source: Fong’s
Knit processing sequence

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Process sequence – dyeing
Spun oil washing Heat setting
Finishing Dyeing
Tubular slitting

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Process sequence – printing
Spun oil washing Heat setting Printing
Finishing Washing Steaming
Tubular slitting

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Total solutions for active wear processing
Slit opener/rope
opener
 Spun oil washer
 Print washer
 Beam batching
 Stenter
 ALLFIT – softflow dyeing (sampling)
 ECO 8 – jet dyeing
 ECO 88 – high speed jet dyeing
 TECWIN – soft flow dyeing
 CBS - beam dyeing
 AIRJETWIN – air flow dyeing
 DYECOWIN – dyeing machine
 Digital printing machine
 Rotary printing machine
 Loop steamer
 Coating head
 Dyes, chemicals
 Print paste dispensing
 Weft straightener
 Process control system
ETP

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 The machine is designed to slit the
tubular fabric with or without drop stitch
 Easy handling
 Minimum elongation
Dry slit opening plant for tubular knit fabric

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 Low tension fabric transport ensures reduced elongation to synthetic knitted fabrics
 Complete removal of oil through high turbulence wash with kinetic energy
 Sintensa cyclone drum washing system offers a combination of low liquor, power spray and turbulent
wash that ensures perfect washing
 Thermplate indirect heating system offers uniform heating throughout the compartment
 Self cleaning rotary filter system, heat recovery system and automatic chemical dosing system
Spun oil washing range for synthetic fabrics

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 Fabric type: warp/circular knit/woven
 Fabric quality: polyester/nylon with Lycra
 Machine speed: up to 40 m/min
 Chemicals: soda ash, washing agent, acetic acid (optional)
Oil removal Washing Neutralisation + washing
Spun oil washing range for synthetic fabrics

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CBS – HTHP fabric beam dyeing machine
 Suitable for wide width fabrics which are sensitive
and with high content Lycra
 Equal capacity preparation tank with direct heating
facilities and high temperature drain device can
shorten the process time
 Dual flow function equipped with flow reversal device
 Safety inter-lock for high temperature and high
pressure operation
 Accurate temperature control through fuzzy logic
technology keeps dyeing temperature constant which
ensures levelness in dyeing

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DYECOWIN – HTHP dyeing machine
 Fabric speed can reach up to 600 m/min for light
fabrics
 Suitable for handling the fabric weight up to 350
GSM
 Suitable for various synthetic fabrics such as warp
or weft knitted with 100% polyester, 100% nylon,
polyester/spandex and nylon/spandex
 Effective unloading design: unloading device
made of stainless steel with high grip materials to
increase lifting force; achieving an effective
unloading operation

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DYECOWIN – HTHP dyeing machine models

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 Integrated intelligent rinsing system helps to
reduce the amount of water used for rinsing
by accurately determining the quantity of
water required
 PLC ensures high degree of reproducibility
by controlling process parameters
 Any slight changes in the process are
clearly shown in real time for analysis
TECWIN – HTHP soft flow dyeing machine

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TECWIN – HTHP soft flow dyeing machine

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AIRJETWIN – HTHP airflow dyeing machine
 Single blower for multi-tube machines
 Integrated nozzle system; both overflow and spray nozzles
are provided
 Integrated intelligent rinsing system helps to reduce the
amount of water used for rinsing by accurately determining
the quantity of water required
 PLC ensures high degree of reproducibility by controlling
the process parameters
 Any slight changes in the process are clearly shown in real
time for analysis
 Overhead cleaning systems
 Effective unloading system
 Variable loading chamber

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AIRJETWIN – HTHP airflow dyeing machine models

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ALLFIT – HTHP soft flow dyeing machines for sampling
 High reproducibility
 High automation: Advanced process control and
automation
 Compatible for production: Similar liquor ratio and cycle
time as like bulk production machine, designed for small
and medium batches
 Plug and run: The installation of the machine is easy and
simple

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 Double guide rings per tube enhance
productivity; max loading capacity per tube
is 550 kg
 Uniform dyeing results
 Various automatic control devices, multi-
function stock tank (MST) and control
software enable the ECO-8 to perform the
shortest dyeing cycle of around 298 minutes
per batch
 Optional multi saving rinsing system (MSR)
available for additional energy saving
 Lifter reel speed 250 ~ 400 m/min
 Suitable for fabric having the weight of 200 ~
700 GLM
ECO-8 – HTHP jet dyeing machine

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 Fabric speed of 600 m/min ensures stay time of around 2
minutes in the dyeing chamber
 Fast bath turnover rate; circulation pump provides high flow
rate to sustain the high fabric speed
 The fabric spreads over the whole length of the kier so that
the fabric is not subject to high stack loading, thus reducing
the formation of crease marks
 Sloped kier assists the smooth forward movement of fabric.
Upward sloped front kier helps lift up the fabric rope from
the pile
 When tangling occurs, the reversing nozzle ejects the fabric
rope back into the kier, which helps to untangle the fabric
 The fabric rope immersed in the conveyance tube helps the
dyestuff exchange for evenness in dyeing
ECO-88 – HTHP high speed jet dyeing machine

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 Maximum printing width: 160 to 320 cm
 Maximum number of colours: 4 to 24
 Repeat: 640 -1018 mm
 Squeegee type: magnetic and blade
 Mechanical speed up to 100 m/min
Rotary screen printing machine

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 Zimmer’s Colaris model is a high-performance
digital printer for special application like terry
fabric
 The printer is supplied with Fuji make StarFire™
SG1024-SA/MA/LA print heads, which provide
highest print performance and reliability
 The printer can be supplied with maximum 64
print heads
 The printer is with open ink system, it can be
used with reactive, acid, disperse and pigment
ink
Colaris – digital printing machine

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 Working width: 2000, 2600, 3400 mm
 Fixation time: 5 – 40 min
 Cloth capacity: 60,140, 240, 340 and
440 meters
 Maximum mechanical speed: 25, 30,
50, 60, 70 meters/min
 Ensures uniform steaming
Modus – loop steamer for development of colours

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 All in one machine; screen, knife and
transfer roller coating system
Magnoroll coating head

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Soaping
(15-20 min.)
Remove unfixed
dye
WashingSwelling (2-3
min.)
Softening
optional
Neutralis
ation
Print washer
 Low tension fabric transport ensures reduced elongation to synthetic knitted fabrics
 Sintensa cyclone drum washing system offers a combination of low liquor, power spray
and turbulent wash that ensures perfect washing
 Thermplate indirect heating system offers uniform heating throughout the compartment
 Self cleaning rotary filter system, heat recovery system and automatic chemical dosing
system

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 Dyes and chemicals dispensing
system for exhaust dyeing
 Mother paste dispensing
 Lab dispensing system
 Print paste dispensing system
 Dyes and chemicals storage
with automatic weighing system
Automatic dyes and chemicals and print paste dispensing system

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 Long term lubrication chain
 Life-long lubrication-free spindles
 Heat recovery system
 Individual drive for chain
 Integrated exhaust system
 Lift-O-Mat doors
 Qualitex PLC -750 with 10,000 recipe storage
 Monformatic software to control the process
parameters
 Teleservice facility
Montex 6500 – stenter

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Weft straightener
 Online monitoring and regulation of all relevant
parameters
 Bow and skew corrections
 PLC control for reproducibility
 Available with hydraulic and electric version
Process control systems
 Exhaust moisture controller
 Residual moisture controller
 Fabric dwell time controller
Weft straightener and process control systems

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Package solution for wastewater treatment

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Our references in India
 Paragon International Limited, Unna (Himachal Pradesh)
 Sportswear and comfort wear for Adidas and Reebok
 T-shirts, polo shirts, jackets, capris, etc. for Levi's, Bugatti, Callaway, Kappa, Skechers, Waste2wear
 Performance wear for Alcis
 Versatile Enterprises Private Limited (Ludhiana)
 Artificial fur
 Laminated and coated fabrics
 Insoles and foot beds
 Bonded fabrics
 Manufacturers of garments such as: membrane/water resistant bonded jacket, cotton/acrylic/acrowool
sweaters, fleece jacket, softshell jackets and activewear clothing
 Saachi Processors Private Limited (Ludhiana) and PI Cottex Private Limited (Ludhiana)
 Commission dyers that work with cotton, synthetic, and blends and manufacture garments
(such as sportswear, comfort wear, gym wear, casual wear) for Adidas, Puma, Nike etc.
 Menaka Cotton Mills Private Limited (Theni)
*Global references of our principals available on request

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THANK YOU