Knitted fabrics on large-diameter circular knitting machines are manufactured as endless tubular fabric with a circular array of knitting needles. In double-jersey machines, needles are arranged in both the cylinder and in the dial, while single-jersey machines use knitting-machine needles as well as sinkers. In shirtmaking on bodysize machines, for example, this eliminates lateral seams. This is particularly advantageous for skintight clothing.
Typical application fields in circular knitting include the manufacture of outerwear such as T-shirts, leisure and sportswear, underwear and sleepwear, among them bra fabrics and technical textiles such as smart shirts.
However, knitted fabrics on seamless bodysize machines, in contrast to large diameter circular knitting machines, are manufactured as individual items and not pulled off as tubular fabric, but rather ejected individually. Circular knitting machines with corresponding diameters are used for the different fabric sizes. For this Groz-Beckert provides high performing needles and system parts such as knitting cylinders.
Typical application fields are the manufacture of medical textiles, underwear and outdoor underwear, bodys and swimwear.
Thanks to a wide variety of options, circular knitting technology is perfect for manufacturing stylish and functional textiles – from undershirts and T-shirts to upscale sportswear.
Circular-knit fabric provides many benefits: it is elastic, seamless and cost-saving to produce and can be used almost anywhere. This flexibility makes it of particular interest to the clothing industry.
The manufacture of clothing is the largest application field in circular knitting. Different fabric structures and gauges provide for an enormous variety of designs and functions. High requirements are made on functional knitted fabrics for sportswear; for instance on their stability and moisture-wicking. Beyond that, T-shirt and sweatshirt fabrics must be fashionable, whereas comfort is the main consideration for underwear.
A somewhat unfamiliar field of application for circular-knitting technology is the knitting of mattress fabrics. There is presently a change in technology taking place – away from weaving to the more cost-effective and flexible knitting.
In contrast to woven mattress fabrics, knitted fabric is elastic and provides other advantages that a woven fabric cannot offer without using cost-intensive yarns. These include greater fabric volume, higher fabric flexibility and air permeability. Everything needed for a good night's sleep.
The higher flexibility and elasticity, in particular, make knitted mattress fabrics interesting, since they better adapt to body movement.
Knitted fabrics also offer more patterning options. End users thus dispose of a greater selection of patterns so that the product range correspondingly expands.
Whether upholstery, headrests, door panels or roof liner – knitted fabric is ubiquitous in automobiles, although not necessarily visible at first glance. Knitted fabrics play an important role in the automobile industry. Especially in car interiors, there are amazingly many knitted constituent parts.
High requirements are made for the products. Safety standards are high, and design and functionality of extreme importance. Especially in vehicle interiors, textiles are exposed to solar radiation and high temperatures. Knitted fabric must withstand these stresses for many years.
Lastly, the higher elasticity and tensile strength of knitted textiles make them the go-to choice. Because of the higher elasticity the knitted fabric is more suited to draping and can be used anywhere.
In addition to textiles made of knitted yarns, knitted fabric made of other materials, such as metal, are also used. They can be found in radiator hoses, airbags and vibration absorbers.
Groz-Beckert has the widest range of latch needles and provides service for all applications – and in gauges up to E90.
Groz-Beckert latch needles guarantee the best fabric quality, including in the finest knits. Productivity is effectively boosted with high speeds. At the same time, Groz-Beckert latch needles can achieve energy savings which lower production costs.
litespeed® and litespeed® plus
litespeed® needles have been designed for use in circular knitting machines. They lower machine temperature and cut power consumption for noticeable cost reduction.
The litespeed® needle is characterized by a partial reduction of the thickness of the needle shank on one side, the litespeed® plus needle by a partial reduction of the thickness of the needle shank on both sides.
The cut-outs on the needle shaft lead to less rubbing in the needle trick, resulting in lower machine temperature. High temperatures can reduce the speed of modern high-speed circular knitting machines. The use of litespeed® needles can effectively counter this and facilitate maximum machine speed. Another advantage of the litespeed® needle is the optimized lubricating properties, since the partial reduction of the needle shaft allows for better distribution of oil in the needle trick.
Costs are not only cut by the reduction in power consumption, lower maintenance and auxiliary costs resulting from less wear of all system components guarantee potential savings. The litespeed® needle furthermore enables longer service life. A welcome side-effect is significant reduction in CO2 emissions, brought about by lower energy consumption.
The manufacture of ultra-fine knitted fabric requires high needle precision. Groz-Beckert offers the optimal solution with the impressive features of the Vo-LC™ needle.
Groz-Beckert guarantees the best fabric quality even at very fine gauges with the most precise needle available on the market – the Vo-LC™.
The needle shines with high dimensional accuracy and numerous patented details, as well as proven Groz-Beckert product features such as G00 technology. The Vo-LC™ needle can produce ultra-fine knitted fabric with optimally uniform loop structure - and at maximum machine speed.
The G00 technology prevents streaks caused by bent-open hooks. This facilitates increased process reliability at maximum productivity, as well as reduced fabric waste.
The special feature of the G00 hook is its low plastic deformation. This means that the hook breaks right after exceeding its limit of elasticity. The resulting fault is immediately recognized, the machine stops and the broken needles can be replaced. The G00 hook is used in particular when the needle hook must withstand unusually high amounts of stress, for example, from knots or slubs in the yarn or when special constructions are knitted.
With this special needle technology, loops can be transferred to adjacent or opposite-side needles. This increases the variety of patterns on the machines employed.
With the transfer technique, high quality pierced patterns, also called Petinet patterns, can be manufactured on single-cylinder machines. Transfer needles have a transfer area in the form of a wing (= transfer wing) between the loop-forming part and the needle butt. This wing is an integral part of the needle shank. Supported by the transfer wing, a loop can be transferred from one needle to an adjacent needle on the same needle carrier. This makes transfer possible in one direction within the same needle carrier. The use of needles with spring plug in appropriate double-jersey machines enables transfer of loops from cylinder to dial and, if necessary, from dial to cylinder. Knitting components must be precisely aligned with one another for a secure transfer process. Moreover, knitting quality is significantly influenced by the uniformity and finish quality of the needle and the transfer clip.
Spring-loaded latch needles
The specific build of the needle, which provides for automatic lifting of the needle latch in closing and open position, delivers many benefits to the loop formation process.
By using Groz-Beckert spring-latch needles, complex knitting processes and high quality demands can be implemented on loop structure. This needle is one of the major innovations in the field of needle development and ensures high process reliability, as well as a high degree of flexibility with regard to pattern options and yarn employed.
Steel composite needle
The needle with double low profile provides ideal damping for high-speed use. The cut-outs of the needle are filled with a special plastic to prevent the accumulation of dirt.
Specifically when working with staple fiber in high-speed machines, much fluff is generated which mixes with oil and metallic debris and accumulates in needle cut-outs and grooves. The patented steel-plastic high-speed needle from Groz-Beckert provides the solution.
SAN™ SF special application needle
SAN™ SF is a special application needle, designed for knitting staple fiber yarn on circular knitting machines. It increases the intervals between cleaning cycles as it counteracts the accumulation of lint.
The shank closed at the lower edge and provided with humps at the upper edge effectively helps to minimize the accumulation of fiber residues between the needle and the bottom of the needle trick. This increases the intervals between cleaning cycles and significantly reduces defects like contamination-related vertical lines in the fabric. The user benefits from lower costs and increased productivity. The most effective solution is the combination of the special application needle SAN™ SF and the staple fiber sinker SNK SF.
Groz-Beckert sinkers ensure a uniform long-term knitting process and flawless fabric. Short setting periods and reduced idle times provide for high productivity.
Staple fiber sinker SNK SF
SNK SF staple fiber sinkers counteract lint accumulation in the verge ring when knitting staple fiber yarns.
When knitting staple fiber yarns in large diameter circular knitting machines, accumulations of fiber residues can result in deposits in the tracks of the needle and sinker carriers. Over time these deposits can result in uneven seating, tight movement and overheating of the needles and sinkers in the knitting machine.
The special shape of the SNK SF sinker with its opening in the front counteracts lint accumulation in the verge ring.
The most effective solution to reduce lint accumulation and significantly extend the time between cleaning cycles is a combination of the SNK SF sinker and the special application needle SAN™ SF. Increased productivity and reduced maintenance efforts are the result.
Secured spring force, constant reaction time and good rounding ensure reliable functioning of selected elements. This prevents erroneous selection, thus increasing customer profits.
The requirements for selected parts are steadily rising because of higher machine speeds, higher system density and finer gauges. Nevertheless, optimized surfaces at crucial points, weight reduction and optimum setup of selected parts in close cooperation with mechanical engineers ensure functionality and safe selection.
Coupling parts are used as connecting elements between needles and selected part. Coupling parts play an especially important role in the manufacture of jacquard patterns.
The perfect interaction of needle and coupling part is ensured by close collaboration between mechanical engineers. Joint development projects provide for process reliability and high quality products.
The separator is used as connecting piece between needle and selection element. It ensures that a specified needle is securely positioned and performs the right knitting function.
In contrast to other coupling parts, the separator is not engaged. This means that it is not connected to the needle, but is located separately in the needle trick and can be separately moved.
During the loop-formation process, holding-down jacks ensure that the knitted fabric does not ride up, replacing the holding-down function of the sinker.
Groz-Beckert cylinders are highly precise, highly wear-resistant and have a long service life. The gauges run from E3–E90 and are supplied for single-jersey and double-jersey machines.
As a full-service provider of cylinders, needles and sinkers, Groz-Beckert offers its customers systems precisely customized to their requirements. High production accuracy minimizes knitting-in and changeover time when changing cylinders and boosts productivity. Groz-Beckert also develops custom-made products upon request. Diameters of up to 60 inches are possible.
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