EcoStar® 


EcoStar®

EcoStar® - durable, energy-saving, sustainable


To provide the maximum benefit, the EcoStar® has been adjusted to suit the changes in the production process.


The EcoStar® needle excels due to
 

  • Extended service life
  • Improved surface of the finished product
  • Lower penetration force without compromising efficiency
  • Reduced energy requirement

 

Benefits of the EcoStar®


Service life


Field tests performed on the new EcoStar® felting needle clearly indicate improved wear characteristics.

Automotive felt - produced using the EcoStar® felting needle

Product surface


Internal and external tests performed on customer premises testify to an optimum product surface. Particularly in automotive engineering and filtration applications, as well as with synthetic leather, the EcoStar® produces a more even fabric appearance than when using standard felting needles. This is achieved by reducing the needle cross-section area by 13 % which also has a positive effect on material displacement and reduces the sizes of penetration holes.

Penetration force


The convex shape of the working part core with its edges offset evenly by 120° permits the felt to be penetrated using a less force. A direct comparison with a standard felting needle is illustrated in the diagram on the right.

Energy reduction


When working with high fabric weights, the EcoStar® can also drive down energy consumption by up to 7 %.

In precise terms, this can mean energy savings of up to 1 kWh compared to standard felting needles. Extrapolated over a calendar year (180 working days) and with a machine capacity utilization of around 85 % (machines run for 20 hrs/7 days), this corresponds to savings of 328 € at a price of 0.1 € per kWh. The reduced energy consumption is due to the even tighter looping angle of the fibres at the undercut.

In addition, the more slender needle cross-section also exerts a positive impact due to reduced material displacement during penetration. 

Special features of the Groz-Beckert EcoStar® felting needle

 

Compared to standard felting needles, the cross-section surface is reduced by 13 %.
However, this material saving does not negatively impact the EcoStar®'s fracture and bending behaviour.

The vertically projecting edges lend the needle substantially higher stability. This allows the same fracture and bending properties to be achieved with a considerably reduced cross-section area with a standard needle.

Smaller looping angle

Working part cross-section of the EcoStar®

The RF barb of the EcoStar® has been modified in the area of the barb radius at the transition to the undercut as a result of the new edge geometry. The distortion created as the barb passes through the material is reduced compared to other needle geometries.

EcoStar®

Standard

The modified geometry in the edge area with rectangular shaped edge surfaces causes the edge angle to be almost parallel. This creates a smaller fibre looping angle, resulting in improved fibre adhesion at the undercut, and consequently a more compact integration of fibres into the felt.

In all fields of application tested to date, it has been possible to exchange a standard needle for the EcoStar® with a minimum of resetting effort, and without any negative impact on product characteristics. Changes to machine parameters are a thing of the past. This needle permits a user-friendly, trouble free expansion of a customer's product range.


Application segments


Automotive, filtration, synthetic leather, home textiles, apparel textiles, geotextiles, medical and waste fibre products

When producing felt, process reliability and reproduction accuracy are vital. Only with these in place can a consistently high standard of quality be assured.

To meet this demand, EcoStar® felting needles by Groz-Beckert are produced with a guarantee of absolute uniformity with tolerances within the range of thousands of a millimetre. This degree of precision provides the absolute assurance of barb dimension accuracy – from one needle delivery to the next.


Groz-Beckert is happy to support you with the adaptation of your production processes. You can find out more about the EcoStar® in the relevant product brochure under "Further Information".