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The Production Process behind the Socks

 The production process behind the socks

In fact, many people do not know that socks is just a general term. According to the raw material, there are cotton socks, wool socks, silk socks and all kinds of chemical fiber socks. According to the length, there are many styles and varieties such as quarter socks, crew socks, ankle cut socks and no-show socks, as well as flat mouth, ribbed, heeled, non-heeled, jacquard and woven patterns. How are these various socks produced? To knit a complete shape of sock, the knitting method and process will vary depending on the type of sock and the characteristics of the sock machine.

Socks process

1) The overall manufacturing process of socks:

1. Socks design───Raw material color proofing───Order raw materials───Sock proofing───Determine the process

2. Socks production — inspection of socks —- —stitching and cuffing — shaping and ironing —Finishing and packing

2) The specific weaving process of socks:

1. Dividing the socks into men’s, women’s and children’s according to different countries, regions, different seasons, different occasions, different occupations and different price points.

2. The sock factory selects different main and secondary raw material and jacquard materials, also makes sample and pre-production samples respectively according to the needs of customers’.

3. According to the selection of sample socks by customers, factory starts to buys a large amount of main and secondary raw materials and jacquard materials.

—Socks are mainly composed of three aspects:

-Main materials: various types of fibers (natural, synthetic, regenerated), which make up the basic structure of socks.

-Secondary material: elastic fiber, which can shrink the sock close to the instep and prevent the sock from slipping.

-Auxiliary material: elastic band, which can shrink the sock cuff and avoid the sock cuff from falling loose.

-Jacquard yarn: make various exquisite patterns, mainly composed of high elasticity, nylon, acrylic and cotton yarn.

4. The engineers of sock factory will develop a scientific and reasonable sock weaving process based on customer‘s selection.

5. The sock factory starts the sock weaving process according to the weaving process (processing on the sock machine).

When the sock comes out of the machine, it is a circular cylinder which is formed by a thread that is continuously wound around. One Side is sock cuff (with elastic band), and the other side is sock toe (the finished product is stitched ,toe area). The worker will turn the sock over to the reverse side, and proceed to the next step of stitching.

6. Take the socks off the machine for inspection, and start the sewing head manufacturing process for qualified products.

After stitching, the cylindrical stockings are transferred to the sewing head manufacturing process. According to the product sewing requirements, they can be divided into manual sewing and machine sewing.

Manual sewing is also called boneless stitching. Stitching the toe part of the sock onto the disc-mounted needle disc by hand stitching.

Machine sewing means that the worker needs to put the toe part on the machine, and the machine stitches it directly.

The two sewing methods have their own advantages and disadvantages. Compared with manual sewing, machine sewing has the advantage of fast production speed and suitable for mass production, but it is not smooth and comfortable to wear by hand. However, manual sewing socks are smooth and comfortable to wear.

7. Thoroughly inspection after head sewing process.

It is very necessary to conduct a professional and comprehensive inspection after head sewing process, because knitting and sewing are the most important parts to check for defective products. By setting up inspection after the sewing process, we can improve the product qualification rate and reduce the waste of capacity in the later process.

Unqualified products will be put into the waste warehouse, and qualified products will be transferred to the heat setting process.

8. Transfer the qualified products into the heat setting process.

Put socks on metal panels of various specifications and high temperature and pressure generated by boiler steam will shrink the inner elastic fibers and smooth the fluffy shape or folds of the sock surface. Then, after drying and cooling operations the sock surface can beshaped.

Generally, socks are ironed at 2 atmospheres. The shaped socks (must be naturally dried for 48 hours) before they can flow into the socks matching process.

In general, we use 2 atmospheres of pressure to do the sock ironing process.

After heat setting process(must be naturally dried for 48 hours), the socks can be transferred to matching process.

9. The matched socks will be sorted in the semi-finished product warehouse according to the item number and color. The packaging workshop will pack socks according to customer’s needs, then sort them into boxes, finally put them into the finished product warehouse.

The pair matching can do the final inspection of socks. Match two socks in pair with same length then match the logo according to the requirements and packed them with bag and box as required. Finally just waiting to be shipped to warehouses and outlets all over the world.

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