It is no secret that socks are a popular and practical item. They are worn by everyone from athletes to business professionals. But do you ever wonder where they come from and how they are made? The socks you wear are a complex and unique piece of clothing that can be broken down into several steps. The process begins with the design of the sock and ends when they arrive at your door.
There are several companies that make their own line of socks in America. These companies use different yarns to create their unique styles of socks. Some even use repurposed materials such as recycled plastic bottles. The company Sleet and Sole is a prime example of this as they are one of the few American-based companies that uses REPREVE, a specialized fiber made from three recycled plastic bottles.
Before any sock can be made, the raw materials must be washed and dyed. The dyes used must be OEKO-certified, which means that they are free of harmful chemicals and environmentally friendly. The dyes are then mixed with the yarns to produce the desired color. This step can take up to 4 hours, depending on the type of yarns being used.
Once the yarns are ready, the sock is knitted by machine. During this stage, the socks are inspected for size and length to ensure that they are consistent and correct. Afterwards, they head to the seaming section where they are sealed around the toe. Different types of seaming will be applied such as hand-linking or seamless linking, depending on the type of sock being made.
The next step is to stitch the logos onto the sock. This is where a team of experts who are accustomed to working with the sock knitting machines can make the magic happen. They will translate the vector designs into bitmap codes that can be read by the knitting machines. This will ensure that each pixel of the design corresponds to a specific thread of color in the final product.
In the past, a major part of America’s sock production was done in Fort Payne, Alabama. This city is known as the “Sock Capital of the World” and was responsible for a large percentage of the US’s sock production until recently when China overtook them.
This is due in large part to the massive increase in industrialization and the move towards automation of sock manufacturing. However, America still remains a key supplier of socks around the world and is currently ranked as the seventh largest producer.
It is not a high-tech industry, but it is a very detail-oriented process. Each section of the production must coordinate with each other to ensure a consistent and quality product is produced every single time. The sock industry is a very important economic force in the United States and is sure to continue its upward trend for years to come. We at Zkano are proud to be a part of this tradition in the American Sock Industry and we look forward to continuing our growth into the future. socks factory