Rohleder's focus on service, quality and design excellence
Multi-Matic combines flexibility, efficiency and precision for 100% Made in Germany fabrics.
As one of Europe's most modern weaving mills, family-owned Rohleder has been developing and manufacturing premium 100% Made in Germany fabrics for brands, retailers and private customers for over 80 years.
This success has been due to a consistent focus on design, quality and functionality, as well as by continuous investment in state-of-the-art production facilities. As recently as 2023, a Multi-Matic was delivered to the company's headquarters in Konradsreuth.
Since then, the high-performance warp sampling machine has proven its worth in practice through its high efficiency while also opening up entirely new possibilities in product development.

Tradition meets high tech
Rohleder was founded in 1946 and has grown from a family-run textile business in Upper Franconia into one of Europe's leading upholstery fabric weavers. Key milestones in the company's history include its entry into the US market in the late 1970s under Klaus Rohleder, the shift to functional synthetic fibres in the 1980s and the building of a new production facility at its headquarters in the early 1990s.
Today, the company employs around 165 people and exports its high-quality upholstery and decorative fabrics worldwide. Nearly half of its production is sold internationally throughout Europe, the USA and Asia.
"We stand for service, quality and design excellence" says Leni Rohleder, granddaughter of the company's founder and head of sustainability and marketing. "Together with our textile retailers and wholesalers, we develop exclusive collections that are available only to these partners. In addition, we supply renowned furniture manufacturers such as Rolf Benz, Steelcase, and Sedda with unique products"
Nine designers provide the creative power needed for frequent, rapid product changes and a wide variety of items, even in small quantities. In addition, since 2018 Rohleder has created its own home collection. Particularly durable, easy-care, and high-quality upholstery fabrics are awarded the company's Q2 quality label.


Diversification
These creative concepts are brought to life through a highly flexible, vertically integrated production. From warp preparation through weaving to finishing, all manufacturing steps are handled in-house. In the weaving mill, around 70 machines are in operation, covering nearly the entire spectrum of weaving technology. Many of the machines have been specially adapted to the company's requirements.
"We have one of the most diversified weaving mills in the world," says Leni Rohleder.

This versatility places high demands on warp preparation and whether very coarse or particularly fine yarns, premium warps are produced for a wide variety of fabrics and complex patterns in small and medium production runs.
The partnership between Rohleder and Karl Mayer has been in place since 1998 and is based on mutual trust, technical expertise and shared values.
"We know that things run smoothly with Karl Mayer," says Peter Raich, technical manager of research and development at Rohleder.
He particularly appreciates the reliable supply of spare parts and the expert support provided by the service teams. Thanks to their geographical proximity and long-standing partnership, technical challenges are resolved quickly and easily.
With the installation of the latest Multi-Matic 128, Rohleder has replaced three older warping machines to produce not only sample warps but also production warps with lengths of up to 400 metres.
Short warp lengths, high thread counts and complex warping sequences with up to 400 ends per repeat had previously resulted in a high manual labour burden through creeling, time loss, and waste from bobbins that were not fully used. The Multi-Matic has put an end to that.
"We save 50 to 60% in warping time per month with the Multi-Matic compared to our previous solution," explains technical manager Peter Rödter following a comprehensive analysis of production data.
The analysis revealed that the higher the proportion of pattern warps in the mix with production warps and the more complex the patterns, the greater the efficiency gain. This was impressively demonstrated in a trade show development from the Rohleder designers – an exceptionally colour-intensive fabric with 2,900 threads and twelve colours in a complex distribution that could only be produced with the Multi-Matic
"We can now realise warping sequences that were previously prohibitively expensive, opening up new market segments for us," says Leni Rohled
In addition, sources of error are reduced, as time-consuming manual steps such as frequent creeling and knotting are largely eliminated.

Maximum performance
The Multi-Matic combines flexibility, efficiency and precision in a highly automated warping process. Up to 128 individually controlled yarn guides enable the production of short warps with working widths of up to 3,600 mm, as well as short and medium-length production warps with large patterns, without the need to divide packages by rewinding. State-of-the-art drive control, fully automated stop-free leasing and sizing separation and automatic colour changes with precise yarn laying support production speeds of up to 800 m/min while minimising yarn requirements. High precision throughout the warping process, combined with interactive determination of the optimum creel setup, ensures the consistent production of premium-quality beams.

 

♦ References

►https://innovationintextiles.com

► https://www.karlmayer.com

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