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By Ramana Machines · September 21, 2026
Learn the common causes of circular knitting machine needle breakage, including wrong needle selection, high yarn tension, worn cams, timing problems, yarn quality, machine speed, sinkers, and lubrication.
Needles are important working parts of a circular knitting machine. They move continuously during production and form the stitches that create the knitted fabric. If needles break often, production can slow down and fabric quality can also suffer.
Circular knitting machine needle breakage can happen for many reasons. The problem may be related to the needle itself, yarn tension, cams, timing, sinkers, machine speed, lubrication, or machine settings.
Finding the actual cause is important. Simply replacing the broken needle may not solve the problem if another machine part is causing the damage.
Here are 10 common causes and practical solutions.
Using the wrong needle for the machine or production requirement can cause problems during knitting.
Different circular knitting machines use specific needle types and sizes. The needle should match the machine gauge, needle bed, knitting structure, and production requirement.
Before replacing a needle, check:
Always use the correct needle recommended for the machine.
Excessive yarn tension can put extra pressure on the needle during stitch formation.
High tension may also cause yarn breakage, tight stitches, and uneven fabric.
Check the yarn tension and yarn path. Make sure the yarn moves smoothly from the package through the feeding system to the knitting area.
Make small tension changes and run a test section before continuing full production.
The correct tension depends on the yarn type, machine settings, fabric, and production speed.
Cams control the movement of needles during knitting. Over time, cams can become worn or damaged.
A worn cam may prevent the needle from moving smoothly. This can place extra pressure on the needle and eventually cause it to bend or break.
Check the cam area for:
If a cam is badly worn or damaged, it may need to be replaced. Do not continue making major cam adjustments without proper technical guidance.
The hook is an important part of the needle because it helps form the stitch.
A damaged, bent, or worn hook may not work correctly and can increase the chance of needle failure.
Inspect the needle hook when replacing broken needles. If several needles show similar damage, look for a common machine or yarn-related cause instead of replacing needles one by one.
Needle timing controls when needles move in relation to other machine parts.
If the timing is incorrect, the needle may come into contact with another part at the wrong time. This can cause bending, damage, or breakage.
If needles are breaking repeatedly at a particular position, timing should be checked.
Needle timing adjustments should be carried out according to the machine manufacturer's instructions. If you are not trained to make timing adjustments, contact a qualified technician.
Yarn quality can also affect needle life.
Knots, thick sections, weak areas, or foreign material in the yarn can create sudden resistance during knitting.
This can put extra pressure on needles and other working parts.
Check the yarn before production.
Look for:
Make sure the yarn is suitable for the machine, gauge, and fabric being produced.
Running a machine at a speed that is not suitable for the yarn, fabric, or machine condition can increase the chance of needle problems.
Higher speed can also make existing problems more serious.
Use a speed that matches:
If needle breakage increases after increasing speed, reduce the speed and check whether the problem changes.
Production speed should always be considered together with fabric quality and machine stability.
Sinkers work with needles during the knitting process. A damaged, worn, or incorrectly positioned sinker can interfere with needle movement.
This can cause needle damage or breakage.
Inspect the sinkers when repeated needle breakage occurs.
Check for:
If the same needle position keeps causing breakage, inspect the related sinker and surrounding parts carefully.
Proper lubrication helps moving parts work smoothly.
If lubrication is poor, friction can increase. This can lead to heat, wear, rough movement, and damage to working parts.
Follow the machine manufacturer's lubrication instructions.
Check:
Do not add excessive oil. Too much oil can also create problems, including oil stains on fabric.
Regular lubrication should be part of the machine maintenance routine.
Replacing broken needles is only a short-term solution if the actual cause is not found.
To reduce repeated needle breakage:
Inspect needles for wear, bending, hook damage, and other visible problems.
Remove lint, yarn waste, and dirt from areas around the needles, sinkers, cams, and other working parts.
Make sure the yarn is moving smoothly and the tension is suitable for the yarn and production requirement.
Inspect cams and sinkers regularly for wear or damage.
Do not run the machine faster than the recommended or suitable production condition.
If needles repeatedly break at the same location, check needle timing and related machine parts.
Poor yarn quality can create sudden problems during knitting. Check yarn quality before starting production.
Use the correct oil and follow the recommended lubrication schedule.
When a needle breaks, do not immediately replace it and restart the machine.
Follow these simple steps:
The location and type of needle damage can provide useful information about the cause.
For example, if needles repeatedly break in the same position, there may be a problem with a specific cam, sinker, needle position, or timing.
A needle should be replaced when it is broken, bent, badly worn, or has a damaged hook or latch.
It is also important to check nearby needles when one needle breaks. A broken needle may be a sign that another part of the machine needs attention.
Using damaged needles can lead to fabric defects and may create additional problems during production.
Regular maintenance can help reduce needle problems and unexpected machine stoppage.
A simple maintenance routine should include:
Keeping maintenance records can also help identify repeated problems.
If needle breakage increases after a certain amount of production, the record can help the operator or technician understand when the problem started.
Needle performance also depends on selecting equipment that matches the production requirement.
When comparing machines, consider the machine gauge, knitting structure, yarn type, production speed, automation, maintenance requirements, and availability of spare parts.
A best automatic circular knitting machine should be selected according to the actual fabric and production requirements rather than based only on automation or speed.
After-sales support is also important. Technical guidance, operator training, maintenance help, and spare parts availability can make machine operation easier over the long term.
Businesses looking for a best textile machinery supplier company in ludhiana should compare machine suitability, technical support, spare parts, installation assistance, and after-sales service along with the machine specifications.
Ramana Machines helps textile businesses with circular knitting machinery sourcing, machine selection, installation assistance, operator training, spare parts, and after-sales technical support.
We can help customers identify suitable machinery according to their fabric type, yarn, gauge, production requirements, and machine configuration. We also support China sourcing and imported textile machinery requirements.
If your circular knitting machine is facing repeated needle breakage or you are planning to add new knitting equipment, Ramana Machines can assist with suitable machinery, spare parts, and technical support based on your production needs.
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ViewFind answers to the most common questions about our machines, services and support.
Needles can break because of incorrect needle selection, high yarn tension, worn cams, damaged needle hooks, incorrect timing, poor-quality yarn, high machine speed, sinker problems, poor lubrication, or other machine issues.
Yes. Excessive yarn tension can place extra pressure on needles during stitch formation and may also cause yarn breakage and tight stitches.
Yes. Worn or damaged cams can affect needle movement and may create extra pressure on the needle.
Yarn with knots, thick sections, weak areas, or foreign material can create sudden resistance during knitting and may damage or break needles.
Yes. Excessive speed can increase stress on moving parts, especially when the yarn, machine settings, or machine condition are not suitable for that speed.
Sinkers work closely with needles. A bent, worn, damaged, or incorrectly positioned sinker can interfere with needle movement and cause damage.
There is no single replacement time for every machine. Needles should be inspected regularly and replaced when they are broken, bent, worn, or damaged.
Yes. Poor lubrication can increase friction and wear in moving parts. Following the machine manufacturer's lubrication instructions can help reduce unnecessary wear.
Repeated breakage in the same position may indicate a problem with a specific needle area, cam, sinker, timing, or another nearby machine part.
Stop the machine safely, remove the broken needle, inspect the surrounding area, and check the related needle, sinker, cam, yarn, and machine settings before restarting.
Use the correct needles, maintain suitable yarn tension, inspect cams and sinkers, use suitable machine speed, maintain correct timing, use good-quality yarn, lubricate the machine correctly, and follow regular maintenance.
Get technical support when needles continue to break after basic checks, when timing or cam problems are suspected, or when there is unusual machine movement, noise, or repeated damage to the same area.