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I finally got to test the new Groz Beckert Gebedur Titanium needles (134-35, #23 R)  on the same machine (Pfaff 1245) with the same material and the needle thread shredding is no longer there.

So that fixed the shredding issue.   However, comparing the #23 Groz Beckerts to the Innova #22's that I have been using shows that the #23's are a lot bigger.  

Does anyone have the dimensions of a #22 system 134-35 needle?    I don't care if its metric or imperial.   I'm wondering if the #22's I have are undersized.  I have searched for it, but its not popping up.

#22 is stamped on the shanks of the Innova needles.

I think Innova is the distributor.  The individual packs of 10 only say made in Germany with a small logo.    I've had these needles for a long time.  Its a 100 pack.

The #23 Groz Beckerts are noticeably cutting the threads in the material.  The holes made are clearly shredded just a bit.    This is on Weathermax 80 outdoor canvas which is a very tight weave fabric.

I'm not sure if I should be concerned about that or not.  I'm thinking probably not.

When I run through two layers of Weathermax 80 with a Polyester binding, there is not noticeable tearing on the binding.   The stitches look great. 

This was when the thread shredding became a real issue.   I was occurring when just running through two layers of Weathermax 80, but adding the binding was a killer.  

The stitch formation also appears to be better with the #23 needles.     

So you guys were right.  The needle was the problem.

Thanks for the help!  

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