How Mahlo Reinvented Textile Quality Control Through 8 Decades of Engineering Expertise

Mahlo’s closed-loop control systems optimise product quality and resource efficiency. With tightening energy and emissions regulations in Europe and Asia, are clients explicitly using your systems to meet sustainability compliance targets—or is that still secondary to defect control?
Thomas Höpfl: Sustainability is no longer a secondary concern. In regions with strict environmental regulations—such as the EU and parts of Asia—clients are explicitly using Mahlo’s closed-loop control systems to meet energy efficiency and emissions targets. By reducing waste, optimizing material usage, and improving process stability, Mahlo’s systems contribute directly to sustainability KPIs. The company is increasingly positioning its technology as a compliance enabler, not just a quality tool.

The Orthopac RXVMC is described as the most advanced straightening system in your portfolio. Beyond hardware performance, how critical is software modularity—and are clients willing to pay for smarter diagnostics when ROI may not be immediate?
Thomas Höpfl: The Orthopac RXVMC is Mahlo’s most advanced weft straightening system, designed for high-performance correction of fabric distortions—especially in applications with high distortion dynamics, such as circular and warp knitted fabrics, automotive fabrics, and high-end apparel. At its core, the RXVMC combines mechanical precision with intelligent control logic. It features two independently driven and controlled straightening modules. The first module (at fabric entry) includes three skew rollers and two bow rollers. The second module (at fabric exit) includes one bow roller and one skew roller. This configuration allows fine-grained correction of both bow and skew distortions in small, precise gradations. The rollers are powered by stepless hydraulic drives, enabling smooth and responsive adjustments.

A distortion detection system (e.g., TK12, CK15, or hybrid) is placed at the fabric entry point to detect distortions before they reach the rollers. A second sensor at the exit monitors residual distortion, enabling closed-loop correction. This newly developed actuation concept – a combination of control and actuation – enables an even more precise and faster response to distortions. The use of proven standard components of Mahlo straightening technology ensures high reliability and easy maintenance. The system uses a self-optimizing, AI-enhanced control algorithm that reacts in real time to measured deviations—ensuring fast, accurate, and repeatable correction.

In summary, the Orthopac RXVMC is not just a mechanical solution—it’s a smart, adaptive platform that evolves with the client’s needs. Its combination of precision mechanics, real-time sensing, and modular intelligence makes it a cornerstone of Mahlo’s innovation strategy.

Mahlo’s legacy is rooted in metrological precision. As more industries lean toward predictive analytics and probabilistic process control, how do you ensure your systems remain relevant without compromising on measurement accuracy?
Thomas Höpfl: Mahlo’s core strength lies in the ability to measure physical properties like distortion, thickness, moisture, and basis weight with high accuracy and repeatability. This precision has historically been the backbone of quality control in industries such as textiles, film, and paper. As industrial processes become more complex and data-driven, many manufacturers are moving from reactive quality control to predictive process governance.

Mahlo ensures its systems remain relevant by integrating these capabilities without compromising accuracy. The company uses high-fidelity data as the foundation for predictive models, ensuring that decisions are based on reliable measurements. This balance between precision and foresight is central to Mahlo’s innovation strategy.

Mahlo’s approach is to evolve without eroding trust. In industries where tolerances are tight and compliance is critical, measurement accuracy remains non-negotiable. Predictive features are offered as enhancements, not replacements—ensuring that clients can innovate confidently without sacrificing control.

You mention that 80% of the value in Mahlo systems lies in after-sales, service, and calibration. In emerging markets, where capital budgets are tight, how are you restructuring long-term value propositions beyond initial CAPEX?
Thomas Höpfl: In markets with tight capital budgets, Mahlo is rethinking its value proposition. Instead of focusing solely on CAPEX, the company emphasizes Total Cost of Ownership (TCO). This includes flexible financing, subscription-based service models, and long-term calibration and support contracts. By shifting the conversation from upfront investment to lifecycle value, Mahlo makes its technology more accessible to emerging economies.

Are clients pushing for contractual performance guarantees—uptime SLAs or accuracy benchmarks—moving beyond standard service tiers?
Thomas Höpfl: Yes, clients—especially in high-volume manufacturing—are increasingly demanding contractual guarantees. These include uptime SLAs, accuracy benchmarks, and response time commitments. Mahlo has responded by formalizing service tiers, offering remote diagnostics, and building performance metrics into its service agreements. This shift reflects a broader trend toward accountability and measurable outcomes in industrial partnerships.

As Mahlo enters its ninth decade, what are the unresolved technical frontiers still facing the company—from non-contact measurement limits to multi-layer analytics? Where do you expect your next major performance leap to come from—materials science, optics, or software?
Thomas Höpfl: As Mahlo enters its ninth decade, the company continues to face—and embrace—complex technical frontiers that will define the next generation of measurement and control systems. Mahlo’s strength lies in combining deep vertical integration (all systems are developed and built in-house in Saal an der Donau) with global market insight. This allows the company to respond quickly to emerging technical demands while maintaining the precision and reliability that define its brand. Mahlo’s future is not just about measuring more—it’s about understanding more, predicting earlier, and controlling smarter.