Tufting
The whole nine yards – from individual parts to the overall system
Groz-Beckert has been manufacturing products for tufting machines for more than 20 years. In addition to tufting needles and tufting knives, the range also includes loopers and reed finger modules. In the form of tufted textiles, they create the floor on which we walk and stand. This not only includes carpets, bath mats or floor mats for cars, but also artificial turf for landscape design and sports facilities.
Tufting machines can be up to five meters wide. Up to 4,000 needles, loopers, reed fingers and knives are used in the machines at maximum speeds of 1,800 rpm. Premium tufting products from Groz-Beckert, which can be purchased as individual parts, as modules or as a perfectly integrated complete system, produce high-quality textile surfaces.
The product range
Single needles and needle modules
Single needles and needle modules
In mechanical tufting, the needle is used to insert the so-called pile yarn into the backing material. The needles are arranged in a row according to the product width and pierce the backing material at the same time.
Groz-Beckert offers tufting needles as single parts or as a module with up to 24 needles. The use of modules minimizes setting periods and ensures precise needle positioning.
The Groz-Beckert product range includes all common needle types. The needle modules are available in all gauges with the relevant fixing systems.
All products are characterized by consistently high precision and running performance.
Loopers and looper modules
Loopers and looper modules
The task of the looper is to remove the yarn introduced into the backing material from the needle and hold it while the needle retracts. This creates loops of thread on the surface of the backing material, which produces a tufted surface when repeated.
There are different types of loopers due to the different tufting processes. This includes both looping and trimming loopers. There are numerous versions for each looper type, with geometries adapted to the machine type and the application.
Loopers are also available as single parts or as modules, each with different fixing systems and in different gauges. All loopers are designed for optimal interaction with the needle.
Reed finger modules
Reed finger modules
In mechanical tufting, the reed finger modules are responsible for supporting the backing material during piercing. High precision is essential here due to the space requirements for the needles and the yarn in the space between the reed bars.
Reed finger modules from Groz-Beckert offer this precision and thus ensure a uniform and flawless fabric appearance.
Groz-Beckert reed finger modules are available in straight, offset or combination versions and in all gauges and fixing systems.
Tufting knives and knife modules
Tufting knives and knife modules
Depending on the machine type and the type of carpet desired, the loops can be cut open during the tufting process. Groz-Beckert offers tufting knives in all versions and for a wide range of applications.
In combination with the trimming loopers, tufting knives from Groz-Beckert ensure uniform trimming and thus an optimal appearance of the final product. The knives can also be supplied as a cast module for very fine gauges.
Gauge part systems
Gauge part systems
The gauge part system combines all tools required for the tufting process in a single product. Needles, loopers, reed fingers and, if necessary, knives can be supplied in a single module. The individual components of the gauge part system are perfectly coordinated and thus offer optimum functional interaction.
Gauge part systems from Groz-Beckert are available in different versions for all applications, such as Loop Pile, Cut Pile, Cut Loop and Level Cut Loop.
It pays to use gauge part systems from Groz-Beckert: You get all components from a single source and benefit from a complete system manufactured from extremely high-quality materials and subject to strict quality guidelines in production.
All gauge part systems are available with the most common fixing systems. The patented "GB Fit" enables easy insertion and precise positioning of the entire module in the machine.
Tufting technology
The term "tufting" refers to a sewing-machine-based technology for the manufacture of carpets and other products such as high-quality automotive interior lining or artificial turf for sports facilities and landscape design. During mechanical tufting, needles insert the so-called pile yarn into a backing material (woven fabric or nonwoven). Up to 4,000 needles pierce the backing material at the same time. Before the needles are retracted, loopers hold the yarn in place, creating loops on the upper side of the backing material and thus a textile surface. Finally, the pile knobs are fixed on the rear side with a coating and, if necessary, provided with an additional layer, a so-called second backing.
The loops can also be cut open or different processes combined depending on the desired carpet type. Overall, a distinction is made between four different manufacturing methods:
Loop Pile
Loop Pile
Loop pile fabric is manufactured using the Loop Pile process. The carpet surface is formed from individual loops of yarn. Carpets manufactured using the Loop Pile process are considered particularly robust.
Cut Pile
Cut Pile
With the Cut Pile process, the yarn loops are cut open in an additional work step. This creates velour carpets. A special cutting system is used for this purpose, which works based on the scissor principle with the help of tufting knives and trimming loopers.
Cut Loop
Cut Loop
The Cut Loop method combines Loop Pile and Cut Pile. Only selected loops are cut open, creating a combination of loop pile and velour fabric.
The yarn tension determines which loops are cut open. Loops under normal tension remain on the looper and are cut open (= cut pile or velour), while loops under high yarn tension are pulled off the looper and retained as a loop (= loop pile).
Level Cut Loop
Level Cut Loop
Another special combination of Loop Pile and Cut Pile is the Level Cut Loop method. The individual loopers are controlled via a pneumatic closer, which creates a programmable pattern of loop and velour. Additional servo motors also generate different yarn tensions, which enables further patterning effects.
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