Socks Manufacturing Process

Introduction: Socks
Socks is type of cloth manufactured by the knitting technique, it covers the foot and leg complete or partial. There are many types of socks used for casual, sports and medical purposes. Socks make your foot comfortable and warm. Socks are available in various colors, sizes and materials.

Raw Material is very important quality and performance factor in Socks. when choosing, buying and manufacturing the socks the two parameters are kept in mind 1.health conditions and 2.allergies problems of user because e.g. some fibers are beneficent for patients (diabetic) and some may cause the allergy problem, some fibers give benefit for a particular time periods and beyond that will cause health problems. One thing should be keep in mind when selecting material and designing socks structure is that the blood circulation does not effected or resisted. Weather and the season conditions are also under consideration when buying or manufacturing socks. The socks outlook is also an important part of sock selection, because the overall appearance of socks make comfortable to the user.

Sock manufacturing stages
Manufacturing of socks start with the manufacturing and preparation of Raw material i.e cotton and synthetic yarn but these can be purchased from and out sources and the with the knitting the socks processing is started then with the series of process given below.

•Knitting
•Seaming
•Wet Finish
•Board Pairing
•Packaging

Knitting
Now a days high tech circular knitting machines are used having a series of knitting needles in a cylinder formation. The yarn packages are placed on the creel portion and fed according to the pre-designed program through the fed system of machine (machines have 2-4 fed systems). The vertical rows of stitches are called Wales, the rows are called courses.

The knitting is the primary step in quality process. Socks are checked at/ from the knitting machine. Before the knitting process is start it is ensured that the raw material selected is of the desire quality and the yarn fed in the creel portion is according to the pre-define program and pattern of knitting after the few samples prepared the grey socks is inspected to meet the requirement such as size, no of wales & courses heel & foot stretch ribs pattern etc

Seaming
The second processing stage of socks is the seaming after the knitting the grey (un-seamed) socks are moved in the seaming section where the front portion of socks is seamed according to the requirement. For the seaming the synthetic yarn is used according to the customer requirement.

Today’s modern technology saves the time and increase the rate of production now a days the machine available for the seaming are completely modern where the socks are automatically turn inside out and vice versa. Before the seaming the socks is pre-turned so that the seam is properly applied on the socks and the appearance of the seam should me inside the socks. When the seam is applied then for the quality purpose the quality auditor is available to verify the seam quality such as the yarn used for the seam is according to the requirement, the thickness of the seam is also checked for the comfort and the finally the appearance of seam whether it is properly align or not because there is a clip (particular knit area where the seam is applied) and in last the machine again turn inside out of the sock.

Wet Finish
After the seam the sock is now in its actual shape in which it should be, now the seamed socks are ready for the application of the wet-finish and therefore brought in the finishing department. Application of wet-finish based of the many steps, these steps vary according to the material and end of the socks.

Now the socks are washed for removing the knitting oils and the waxes applied during the spinning and knitting stages. Scouring and bleaching is also carried out so that the socks should be properly cleaned and does not cause any shade problem during the dyeing and color matching. There are many other axillaries used such here softeners, and antimicrobial finishes according to the quality and customer requirement. Some Socks are prepared from the dyed yarns with a particular pattern therefore it is also kept in mind during the processing that the dyes and chemicals used should not fade out the shade of dyed yarns. Temperature is also important factor I this regard.

Board Pairing
After the application for the finishes the socks are ready to bring in the next section that is Boarding and pairing. Boarding is a process in which socks are put on the hot metal foot frame according to the size and passed through the steam so that the final finished look is given to the socks with not creases on it surface. After the socks boarding the socks are paired and ready for the packing but before the packing a final inspection of the paired socks is carried out so that the proper quality is delivered to the customer.

Packaging
Finally the socks pair is moved for the packing, it is carried out according to the customer demand and style. Finally the socks are ready for the shipment.
I hope you have enjoyed the Making of socks.

Website of RY International - Socks Hosiery Manufacturer