How socks are made is a fascinating and complex process. From a design idea to the arrival of the product at your doorstep there are many steps in between. The function, design and fit of the sock will determine what materials are used, which yarn is spun and dyed and which knitting machine is employed. The raw material that makes up the yarn will also have an impact on the sock’s cost.
The first step in creating a new sock is to work with a professional sock designer to create digital design files that can be used by the factory. This step is called pattern coding and it converts the vector-based design into a bitmap file that the sock knitting machines can understand. Each pixel represents a stitch, so the bitmap is a map of the sock’s pattern.
Depending on the type of sock, the next step in the process may involve adding a logo. This step adds to the production time and adds a significant amount of cost. For this reason, it is best to choose a sock manufacturer that specializes in logo embroidery. These companies are accustomed to this additional step and can provide you with the highest quality results.
Once the sock pattern has been coded, the raw materials are spun into yarn at a yarn mill. The yarn is then sent to the sock factory. Once there the socks are knitted using one of the factory’s high technology Italian Lonati machines. The sock factories that have these advanced machines can produce large volumes at relatively low prices. These factories tend to focus on private label sock production for brand owners and retailers.
When the socks are finished, they are inspected for quality and paired together. Any defective socks are discarded at this stage. The left and right socks are then rolled and packaged. Some sock factories will attach hangtags or bands to the pairs of socks before they are shipped out.
Several of the more well-known and established sock manufacturers are family owned businesses. They are highly dedicated to the protection of the environment and the health and safety of their employees. They are also known for their innovative designs that cater to specific needs, such as outdoor or compression socks. One such company is Nester Hosiery, which was founded in 1993. They create some of the most advanced socks for mountaineers, firefighters, military personnel and athletes.
Aside from their own sock brands, they are also proud to be a trusted supplier of a number of major retailers and brand owners around the world. Some of the brands they work with include, Nike, Adidas, Under Armour and many others. They are committed to producing high-quality products with a short turnaround. This allows their customers to meet the fast-changing demands of their consumers. They have a lot of experience in supplying customized socks and can handle any number of orders. In addition, they can offer a variety of different color options and styles for their clients. socks factory