The family-run business is a vertically integrated facility that focuses on dress socks, compression, and high-performance sporting socks. They also offer a wide selection of colors and designs for your socks.
The hosiery boards are then put into a sock setting machine which is like a large steam oven. This process sterilises the socks and helps them fit better. The socks then get inspected for quality.
Yarn
Socks are made by weaving and knitting strands of yarn. The most common sock yarn is a combination of wool or merino with nylon for stability and elasticity. Unlike the days when socks were exclusively hand knitted, today’s manufacturing process involves industrial equipment and a number of complex steps, including pairing, shaping, and quality control.
To produce a high-quality pair of socks, workers first prepare the yarn manually for the machine. They make sure the yarn is clean and consistent in thickness. In addition, they ensure it doesn’t contain any protruding fibres or knots.
The yarn is then transferred to a transfer conveyor, where it’s sealed with paraffin for 2 minutes to prevent it from ripping during the next stages of production. This step is especially important for long, foot-sized socks, which are more likely to rip or tear than shorter, ankle-length ones. The sealant also prevents the socks from becoming too tight on a person’s leg or foot. The sealant is usually made of natural materials, such as linseed oil or paraffin wax, but some brands use synthetic products like acrylic to reduce their costs.
Design
Sock designers create a wide variety of styles. They use research, global insights, and industry expertise to design socks that are unique and appealing to a wide range of consumers. They also consider color, pattern, and fashion trends in their designs. Designers strive to strike a balance between complex and simple patterns, so they can create socks that appeal to everyone.
Once they have finalized their design, sock manufacturers transform the design into a physical sample. This step helps them assess the quality and fit of their sock before committing to mass production. It can include wear-testing by people within the target demographic, evaluating the sock’s comfort, durability, and performance, and testing the sock’s ability to maintain its shape.
Socks are made on machines that use a multitude of needles to knit the yarn into a series of interlocking loops. These machines are designed to produce a variety of different types of socks. For example, some socks are thicker than others, and some are used for sports. In addition, some socks are embroidered with logos.
Knitting
The sock manufacturing process involves several intricate and essential steps, from designing unique and appealing socks to ensuring that they are delivered in a timely manner to clients. This process can be time consuming, but it is crucial to the success of any sock manufacturer. It includes creating samples, sourcing high-quality raw materials, knitting, sewing and finishing, shaping and steaming, and quality control and pairing.
After the sock sample is approved by the client, manufacturers prepare for mass production by acquiring the necessary raw materials and setting up the sock knitting machines. By following strict quality control measures, manufacturers can ensure that their final products meet or exceed client expectations.
Once the socks have been knitted, they are inspected for any defects or deviations from the approved design. If any problems are detected, the manufacturer can correct the issue before proceeding with the rest of the production process. The socks are then paired into matching pairs based on size, style, and color. The socks are then washed, dried, and shaped on straight metal foot forms (this is known as boarding). Finally, they are steamed to retain their shape and size.
Seaming
The last step in the socks manufacturing process is seaming. Socks are knitted as a tube and then sewn together at the toe end. This eliminates the need for multiple seams, which is better for your feet than having extra fabric bunching up next to your big and pinky toes. Often, these excess fabrics can cause blisters when you wear shoes.
Using the digital design files, a coder at the factory converts them into a bitmap file that the knitting machine can read. The coding ensures that the design will appear correctly on the socks. This is the only way to guarantee that the socks will be the right size and shape.
Once the knitting and sewing processes are complete, the socks are washed and conditioned. This helps to remove any oils and residue from the yarns, stabilizes shrinkage, and makes the socks feel soft. The socks then move to the boarding area, where they are pulled on straight metal foot forms and formed into their final shapes and sizes. They are then paired and steam pressed to retain their flat, neat form.
Finishing
Socks go through a finishing process that includes shaping and steaming. This is important to help them achieve their final form and ensure a comfortable fit for the wearer. This process can also help to relax the fibers and improve their appearance.
Once the socks have passed a quality control inspection, they are then matched into pairs. This is an important step because it helps to ensure that each pair of socks is consistent in size, design, and color. This ensures a professional and polished final product that meets consumer expectations.
The final step in the sock manufacturing process is applying labels. This can include logos, size information, and care instructions. Depending on the type of packaging materials and design preferences, sock manufacturers may also apply a brand logo or other visual elements to the packaging. Finally, the socks are packaged and shipped to their final destination. Throughout the entire manufacturing process, sock manufacturers must adhere to strict quality standards and maintain high customer satisfaction rates. This will help them build long-lasting relationships with their clients.socks factory