1. Raw Materials Sourcing and Dying
We use a wide range of yarns specified by our customers. The yarn used determines the character of the sock: stretch,sweat absorbency,colour fastness,dimensional stability,abrasion resistance, etc.We source all our pre-dyed yarns from top quality suppliers, of which 90% locate at the areas within two hours drive. This ensures that our delivery will not be delayed by late yarn supply, guarantees the quality as we can visit our sources easily and regularly,and makes us very flexible in executing different kinds of orders. |
|
|
2.Programming
All our knitting machines are computerized.According to the socks specifications,our technicians need to make the knitting program in the computer,which we call programming,by using special programming language code. After this,the technicians will input the program into the knitting machines with disk or USB. |
|
|
3. Knitting
The knitting needles are mounted on a single or double cylinder on the knitting machines. As the cylinder turns, the needles interlock loops of yarn, beginning at the top and working towards the toe. |
|
|
|
Single Cylinder Machines (From 96N to 200N) |
|
|
Double Cylinder Machines
(From 84N to 168N) |
|
|
4. Toe-seaming: Hand linking or Machine Linking
When the sock is knitted, the toe remains open. We need to link the toe by using either hand linking, sometimes known as seamless linking, or machine linking,which could also be called rosso or automatic linking.
See the left picture for hand linking. |
|
|
|
See the left picture for machine linking. |
|
|
5. Quality Control
Our QC staffs check the socks one by one for any defects such as missed stitches, holes in the seams or any flaws in the fabric of the sock. Any problem that is discovered will be reported to the line manager for further investigation. |
|
|
| 6. Finishing.The final process in the manufacture of our socks includes below steps: |
|
|
A. Steam Setting
The shape of the sock is set by putting it on flat metal foot form templates and applying heat to it in the form of steam.This gives the sock its shape and smooth appearance. |
|
|
B. Pairing
This is the step we ensure that two pieces of sock we put together match perfectly. After knitting and steam setting,there could be slight discrepancies in size, even from the same consignment. This process eliminates the chances of two socks with different size being put together. This stage also includes regular quality control.
C.Packing
Each customer has their specific requirements when it comes to the stage of presentation of their products. The packagings we can use for the socks may consist of labels, bandrolls, hangers, hang tags, riders,clips,stickers,or anything else that our customer requires. We have long-term contractors to produce all the packagings.Or we could buy them from the suppliers designated by the customers. |
|
|
D.Final Quality Control
The quality of our products is assured through continuous checking and monitoring throughout the whole manufacturing process. The final stage before boxing and shipping is double checking the quality and packaging of the final product by our quality supervisors to ensure it meets both our customer's requirements and our own standards. |
|
|
7.Stocking and Delivery
Our finished products are boxed and kept secure in our warehouse,and will be delivered to the Shanghai port by our reliable transportation contractors before shipping. |
|
|
|
Shanghai Port,is on the east of Hangzhou.It only takes two hours to drive from our factory to this port. |
|
|
