I've seen variation in drag with Badger needles. It doesn't take much change in needle diameter to make a lot of difference. And unfortunately, Badger needle bearings are not adjustable. Well, they are in a way. Here is a video with one method. I've also reamed them with a #55 drill bit, and you can squeeze them from the ends to tighten them. You can also reduce the diameter of the section of the needle that passes through the bearing with some very fine wet or dry paper. But, you shouldn't have to. I would contact Badger either by phone or e-mail and see what they say. Maybe they got a bad batch of needles.
Don