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No hot needles

In the life cycle of a needle set, litespeed needles make a positive contribution to environmental protection and the reduction of production cost of knitted fabric

The challenge in terms of sustainability:

In the production of knitted fabrics in high-performance circular knitting machine, the knitting tools are subject to high temperatures. In practice up to 100 °C can be measured or even exceeded. Customers criticized these high temperatures, especially when operating or maintaining the machine. A reduction of the high machine temperatures by means of active cooling systems is technically possible but involves an additional high energy consumption.
 

The initial position:

As the movement of the knitting needles generates a large share of the frictional heat, it was a great challenge to design the knitting needle in a way to reduce the frictional heat and increase energy efficiency. Already in the 1990s, extensive investigations were made to analyze the influence of the geometry of the needle shank on the temperature behavior of the circular knitting machine.
Years of research and development in cooperation with customers all over the world and machine builders paid off.
The result is quite impressive!

The solution:

The main features of the litespeed needle

  • Optimized needle shank geometry due to partial reduction of the needle shank thickness in circular knitting needles
  • Reduced needle weight
     

he drawing on the right visualizes the geometry of the litespeedneedle. The enlarged image shows the partially reduced areas of the needle shank. This shank geometry makes the needle shank more flexible, making the needle more resistant to breakage at higher machine speeds.

litespeed optimizes lubrication behavior and reduces oil consumption. The partially reduced needle shank allows a better distribution of the needle oil.

Benefits:
• Reduced friction against the trick walls
• Less energy required for needle movement
• Less oil fogging
• Reduced oil requirement due to optimized lubrication

litespeed reduces energy costs – permanently!
The lower degree of friction against the trick walls and reduced needle weight enable easier needle movement.

Benefits:
• Up to 20 % lower energy consumption of the machine
• Less energy required to lower the room temperature
Machine temperature by comparison:
 


The sustainable strengths:

In the life cycle of a needle set, litespeed needles make a positive contribution to environmental protection and the reduction of production cost of knitted fabric.

• Clear reduction of carbon emissions and, therefore, ecological release
• Reduction of energy consumption of up to 20 %
• Reduction of machine temperature of up to 20 %
• Reduction of oil consumption due to optimized lubrication
• Significant increase in performance

Example of energy cost saving using litespeed needles:

Machine:
Single jersey 30", E24, 33 rpm, fitted with 2,268 needles

Energy consumption:
Standard needle: Wo 146.52 G 001 - G 004 3.4 kW
litespeed needle: Wo-LS 146.52 G 001 - G 004 2.8 kW

Difference 0.6 kW (equivalent to 17 %)

Life of the needle set: 4,000 h
4,000 h x 0.6 kW = 2,400 kWh

Energy costs: 0.10 € per kWh

Cost savings per needle set:
2,400 kWh x 0.10 € / kWh = 240 €

Savings per 1,000 needles:
240 € / 2,268 x 1,000 = 106 €

litespeed releases the environment

Reduced CO2 emissions, using the example of a circular knitting machine in India.

CO2 emission standard: 9,730.78 kg CO2
CO2 emission litespeed: 8,215.74 kg CO2

Reduction: 1,512.04 kg CO2 = 1.512 t CO2
(For details on the calculation of emission values, please see technical information leaflet KNITTING 14)

Splendid success with the KYOCERA Environmental Award

On April 29, 2010 in Germany's former Bundestag in Bonn, Groz-Beckert was awarded the KYOCERA Environmental Award. The litespeed needle's enormous reduction in energy consumption and CO2 emission in high performance circular knitting machines – in combination with increased productivity – convinced the jury of high-ranking experts. The decisive factors were innovation, market potential, environmental release, and transferability to other companies.

Brief profile of the company:

Name: Groz-Beckert KG
Headquarters: 72458 Albstadt, Germany
Year established: 1852
Employees: 7,300

Solutions: For more than 150 years, Groz-Beckert has supported the machine builders of the textile industry. During this period, Groz-Beckert developed from being purely a manufacturer of knitting machine parts to the leading supplier of entire systems of precision components in the field of textiles and beyond. Step by step, the company has branched out into the business sectors of Sewing Machine Parts, Felting and Structuring Needles and Gauge Parts Tufting – complemented most recently by the important sector of Weaving Machine Parts, Weaving Preparation and Knitting Cylinders.

With the production of Ceramic Punching components (CPC), Groz-Beckert has meanwhile also become a supplier to the computer and telecommunications industry.

The customers' success is the motive power behind Groz-Beckert's striving for perfection. Groz-Beckert's motto is: top product quality, fast availability, and first-class service.

Numerous innovative ideas and patent, decades of dialogue with machine builders, research institutes, and universities, a world-wide presence with a closely-knit sales network in more than 150 countries. Production sites in Germany, the Czech Republic, Portugal, North America, India, Vietnam, and China. Some 7,000 employees and a unique production know-how:
Internationality: locations or distribution partners abroad.

URL: www.groz-beckert.com