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Socks and its manufacturing

Article · October 2010

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Pardeep kumar Gianchandani

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Socks and its Manufacturing

By: Pardeep Kumar Gianchandani

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.

Production Process Flow fig 1[1]

[1] SMEDA Pre-feasibility report of socks manufacturing 2005

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Socks different parts fig 2

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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
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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.

Process 5: 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.

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Way of Measurement:

A - B: FOOT LENGTH
C - D: LEG LENGTH
E - F: WIDTH OF WELT

Socks Measurement layout fig 3

Socks Used for Different purposes (END USE OF SOCKS)

Slipper Socks
These socks used for casual purpose.

Medical Socks
These Socks used in the medical such as for heeling the wounds, controlling diabetic,
weight loss purpose.

Tube Socks
 These types of socks do not have heel they are longer in length and looking like a tube
shape. These socks used by athlete and for casual wear.
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Crew Socks/ Work Sock / Boot Sock

These provide coverage up-to mid calf and may be worn straight-up, cuffed or scrunched.
They are available in different sizes “ribs” or textures and may be modified as a work sock
or boot sock by adding extra reinforcement and cushioning for extra protection in heavy-
duty shoes.

Cuff Socks
These provide coverage between the ankle and calf and may come in a single cuff, turned
over three times or turned over to show terry loop construction. They can be worn year-
around especially with shorts & dresses, and wear well with all type of shoes except ladies
dress.

Ankle Crew Socks/ Quarter Socks

These cover the foot up to the ankle and wear best with athletic & casual shoes.

Footie Socks / Low Cuff Sock/ Lo Cut Socks

These cover the foot, stopping below the ankle. They are popular in hot weather and are
sometimes embellished with stripes or logo. They wear best with athletic & casual shoes.

“No Show” Socks

These are covered by a shoe for a “no socks” look. They are popular in hot weather.

Anti-Bacterial Socks
This durable finish is added to socks to control the growth of odor-causing bacteria. It
usually will not wash out for the life of sock.

Support Socks
Supports socks are made of nylon & polyester with nylon & elastic fiber added to give
support to the leg & foot to reduce fatigue.

Terry or Cushioned Socks

Terry fabric is used in socks for increase cushioning. It is used mostly in foot of the sock and
can be full or half terry around the sock.

Thermal Socks
These types of socks are used in the winter, the raw material used for the manufacturing of
such type of socks required heavy acrylic, wool, polypropylene or a blend of fibers.   

Material Used in socks manufacturing:

Quality of raw material and knitting type and construction are the main parameters concern
with the comfort and performance. For the manufacturing of socks there are number of
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fibers available and used according to the customer and end use purpose. The Raw material
used for socks manufacturing are among the following fiber types many type of fiber
content / mix blends: Cotton, Coolmax, Merino Wool, Nylon, Acrylic, Polyester, Lycra,
Sulcool, Elastic, Ring spun Yarn, Combed Yarn, Melange , Twisted Yarn, Polypropelene,
Regenerated yarn and many more

TECHNICAL features:
•The socks design and fiber used should have ability to wick out the moisture easily.
•Socks should be treated with the antimicrobial finishes healthier and free of infections to
skin  
•The socks structure should be enough to keep foot ventilated to avoid unpleasant odor  

COMFORT features:
•Socks structure /design should be enough to make foot comfortable
•Socks should meet the environmental and weather conditions to make user comfortable.
•Should have similar pattern and design both sides (left and right)
•When the different types of yarn are used in one sock it should ensure comfort and
performance.  

Heel Type
•Real Heel Socks
•Pouch Heel Socks
•Y-Heel Socks 

Terry/ Cushion Type

•Standard
•Sandwich Terry Socks
•Full terry
•half terry Socks  

Quality Assurance
Q.A Department plays a key role in manufacturing of any product its role start from the
selection of Raw material till the product is delivered to the customer (till customers
satisfaction) it also function with the Maintenance Department and always working towards
the improvement in the quality of product (Socks) .
Customer gives the AQL i.e. acceptable quality limit and Q.A department considering the
AQL of product to play its role and achieve the AQL. At every process of the production, Q.A
staff checks and allow for further process if it is within the range of AQL.
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Process Consists Of

• Ensuring the Quality of Raw material

• Ensuring and monitoring the correct issuance of materials against required Quality
standard of customer.
• Verification at every step of production and packing.
• Final inspection before delivery

There are wide variety and number of test performed by the QAD to make customer satisfied
according to their requirement.

• Yarn testing
oCount
oHairiness
oStrength
oYarn twist
oYarn friction/abrasion
oYarn cone moisture
oYarn torque
oYarn Appearance on black board (Grading for appearance)
oElongation ( For synthetic yarn)
oTenacity ( For synthetic yarn)
oBlend Ration (Fiber composition test For synthetic yarn)
oShade variation ( For synthetic yarn)
• Color tests
o Shade check on spectrophotometer
oColor fastness to washing
oColor fastness to water/chlorinated water
oColor fastness to rubbing
oColor fastness to perspiration
oColor fastness to light

• Stability test
oDimensional stability test after number of washes
oHeel stretch
oFoot stretch
oSize
oPilling and abrasion
•Chemical testing
oIonic character
o% purity
oSolubility
o% of softener applied
•Material consumption test
o Ravelling

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