|
|
The
life of a sock begins with a spool (or spools) of yarn. The sock may
be made of a single type of yarn or a blend of 2 or more different
types. Socks made with blends benefit from the advantages of each type of yarn. |
|
|
|
|
All
socks are made on circular knitting machines. The knitting machine
needles are mounted on a single cylinder (for flat knits) or
a double cylinder (for ribs). As the cylinder turns, the needles
interlock loops of yarn, beginning at the top and working towards
the toe. When socks come off the knitting machine, the toe is
open, but otherwise it looks like a complete sock.
|
|
|
|
|
|
|
The
toe of the sock is closed or seamed on a separate machine. While
closing the toe, the seamer is able to check for any
knitting defects in the sock. |
|
|
|
|
| After
closing the toe, the sock will be bleached if it is to be a
white sock, or dyed if it is to be a colored sock. Some socks
are made with ingrained or pre-dyed yarn and will not need a
trip to the dye house. |
|
|
|
|
|
|
After
dyeing, the socks are again checked for quality and are sent
to be shaped or boarded. |
|
|
|
| In
boarding, socks are stretched dry or moist over flat metal or
wooden forms of the desired shape and size. Heat is applied
which gives the sock its shape, form, and a smooth appearance.
|
|
|
|
|
|
|
After
the socks have their shape and color, they are put into pairs
according to color and length. During the pairing stage, the
pairers again check for quality and clip any excess strings
from the top of the socks. During pairing, the socks are graded
into classifications such as firsts, irregulars, and seconds.
|
|
|
|
| Some
socks may be further embellished with appliqués or decorations
such as lace before heading to the packaging department.
|
|
|
|
|
|
In packaging,
the socks are again checked for quality and placed in the appropriate
type of packaging. Packaging may consist of bags, hang tags,
adhesive bands, cardboard inserts, cardboard backing, stickers,
or labels. |
|
|
|
|
| After
packaging, the socks are placed in cardboard boxes ready for
… |
|
|
|
|
|
| ...shipping
to the warehouse or our retailers. |
|
|
|
|
|
|
Types
of jobs in a typical hosiery manufacturing plant…
|
- Receiving (Yarn
and other materials are received from suppliers, checked
and distributed.)
- Knitters (Use circular
knitting machines to make the sock.)
- Fixers (Set up
the knitting machines and repair any problems.)
- Seamers (Close
the toe on the sock after knitting and check for defects.)
- Sample Dye Department
(Determine the dye formulas/procedures for each color and
style.)
- Dye House (Dye,
bleach, wash, and dry the socks.)
- Quality Control
(Check socks for quality and conformance to specifications.)
- Boarding (Press
the socks into shape and size.)
- Clipping and Pairing
(Put socks into matched pairs, grade socks by quality and
remove any excess strings.)
- Lace Seaming (Add
lace or other embellishments to the socks.)
- Longfold (Store
paired socks and assemble for further processing, including
packaging.)
- Packaging (Apply
packaging materials to paired, high quality socks.)
- Shipping (Dispatch
finished socks to warehouses or retailers.)
- Warehouse (Store
finished socks and assemble customer orders.)
- Truck Drivers (Deliver
finished socks to appropriate locations.)
- Supervisors (Supervisors
include shift supervisors, department supervisors, and plant
managers.)
- Clerical
- Maintenance
|
|
|