Process of Socks Making

Making of A Sock
We have categorized the manufacturing process into five steps. We begin the process with knitting, and then seaming, wet finish, board pairing, and packaging respectively. Let us show you the Making of a sock through the way...

Making_of_a_sock
* Process 1 : Knitting
* Process 2 : Seaming
* Process 3 : Wet Finish
* Process 4 : Board Pairing
* Process 5 : Packaging

Process 1: Knitting Process
Must be imagining the old knitting needles and grand mother on a rocking chair. aren't you? The socks can be made this way too but producing thousands of pairs this would be difficult rather impossible. We use high-tech machinery run by dedicated quality knitters and mechanics.

The high tech circular knitting machines use a series of knitting needles in a cylinder formation. The yarn is fed to the needles row after row through the stands. The rows are called courses. The vertical rows of stitches are called wales. The photo to the left shows the yarn feeding section and the top of the cylinder of knitting needles.

The knitter is the first step in our quality process. Socks are inspected from the knitting machine. A knitter works as a team with a knitting line mechanic. Together they ensure the product is made of the correct fibers, is constructed correctly, and meets or exceeds our standards for sizing, length, cross stretch, and quality parameters.

We have a wide variety of knitting machines for different applications. These machines enable us to use different fibers and technologies to meet our customers’ needs. Knitting is at the heart of what we do. It is the foundation of quality that socks manufacturing is built upon.

Process 2: Seaming / Linking Process
After the socks are knit, the toe seams must be closed. Our sock moves along to the next process which is seaming, where the sock need a toe seam. Once it leaves the knitting machine and after its first quality inspection, the sock goes to the seaming area. Here the toe opening is closed.

We have a number of ways to seam a sock and the selection is based on two simple quality factors. These factors are the quality of the seam itself and the comfort of the wearer. Again, the fibers and the sock’s intended use are considered to determine the appropriate seaming process.

The other seaming methods utilize machinery specifically designed for sock seaming. Our seaming operators align the socks in this machine for seaming. The socks are usually inside out for this process. The clip is a special knit area where the seam will be sown. The clip also has extra fabric that must be removed for a comfortable toe seam. The machine then turns the sock right side out as the final step.

Process 3: Wet Finish Process
Once seaming is completed, the socks now look like socks should and are ready for the next step which is The Wet Finish Process. At our facility the wet finish process can involve many steps. Some steps are common for all socks and others are specific processes for specific socks.

Socks are washed and dried after the knitting and seaming steps. The washing and drying steps do many things. Washing removes knitting oils and residue from yarns. It allows for adding softeners and conditioners for a soft feel. The “feel” of a sock is called its “hand.” Drying helps “set” certain fibers and treatments and can help add bulk to some socks depending on customer requirments.

The cleaning, conditioning, and softening products and amounts used vary for different socks. The temperature of the water and drying also are important in providing the optimum in comfort. Wet Finish area also includes dyeing, scouring, and bleaching operations. Socks that are to be white are either bleached or scoured. Bleaching is an oxidizing process that removes color from a sock, leaving it white. Scouring is a soap bath that removes tints and impurities.

Colored socks are either dyed after knitting or knit with previously dyed yarn. This already dyed yarn is called in-grain yarn. By the use of in-grain yarns, many attractive color blends and combination are possible. We pride ourselves on our sustainable methods and organic treatment processes.

Process 4: Board Pairing Process
After a trip through the Wet Finish area, the socks are ready for the next step which is Baord / Pairing. There are three steps in this activity: boarding, pairing, and a comprehensive quality review.

In boarding, the socks are pulled on flat metal foot forms. The forms are the desired shape and size of the socks. The socks on the forms are steam pressed between two heated surfaces. This gives the sock its finished look. The image at the left shows the boarding of socks. The freshly boarded socks are then paired. Even socks knit with the same yarns, same machines and the same settings will vary slightly. The pairing process matches socks to other socks with the same slight size variation.

The Board / Pair operation is the last phase of the quality program in manufacturing. Product quality is monitored at knitting, seaming, and during wet finishing. The last review is done at board/ pair. Quality issues that are found at board / pair are traced back through the manufacturing procedure to the source, documented, and corrected.

Process 5: Packaging Process
The pair of socks then moves to the final step which is Packaging. Once the socks are boarded and paired, the next step is packaging. The paired socks are either sent to the packaging line for immediate shipment or to fill future orders. Our packaging is driven by requirements of our retail store customers. Bar coding and standardization are inventory practices for many of our customers.

You can fine quality socks at the competitive prices from us...

Website of RY International - Socks Hosiery Manufacturer