The manufacture of socks involves many detailed processes. Each stage of production must be coordinated to ensure quality requirements and time control. In this post, we are going to talk in detail about the sock making process.
Overview of socks manufacturing process
The entire process of making the socks involves many steps, and the coordination between these steps makes the entire process time consuming. When you sort all of the above, there are a total of 7 steps that we will mainly talk about as follows:
- Pattern coding
- Yarn preparation
- knit socks
- Attach / sew socks
- Combine and label socks
1. Pattern coding
What our customers offer us are the sock designs. However, sock knitting machines aren’t smart enough to read the designs directly. A professional coding team familiar with sock patterns and the Mahine mechanism will do this job. You translate your vector designs into bitmap designs and then enter codes that the knitting machines can read. Each pixel of the bitmap design means that a thread with the specific color is knitted through.
Different needles on the knitting machine cause the widths of the flat bitmap designs to be different. 96 N, 132 N, 156 N, 160 N, 168 N of the machines mean that the widths are 96, 132, 156, 160, 168 pixels. Limiting the number of threads is why socks cannot have gradients or detailed patterns.
2. Yarn Preparation
In the order details we confirmed 2 important things about the yarn: composition and colors.
How to choose a suitable composition for your socks.
We also wrote a post on thread color accuracy and recommend using pantone tcx colors.
For normal and combed cotton, we have over 1000 colors in stock that match your Pantone colors.
For other yarns such as merceized cotton, wool etc., we produce individually dyed yarn according to the pantone tcx colors you specify
3. Knit socks
Using the codes programmed in step 1, different needles will knit the different threads into a series of interlocking loops. Computerized sock knitting machines operate at high speeds and can easily be programmed to produce a variety of socks. This is where the 1st inline inspection is performed to avoid errors like length, trimming, locking, etc.
4. Attach / sew socks
Knitting creates a cylinder tube, so we need to go through the sewing process to join the separated toe sections together. This is usually done mechanically, which is quick. Sometimes this process is also done manually, which takes a long time. Since the socks are sewn one by one, our skilled workers can easily find defective socks and remove them from the majority. This is the second inline inspection.
5. Boarding socks
The boarding process is actually implemented to keep the socks in good condition so that they can be easily paired and packaged. Another thing to note here is that the entry-level step also keeps the socks clean and soft by having vapors under a fixed pressure and temperature. After getting in, the socks dry naturally.
Visit our sock making blog to learn more about the sock making process and OEM service.