Our state-of-the-art circular knitting machines use a series of knitting needles in a cylinder formation. The yarn is fed to the needles row after row. The rows are called courses. The vertical rows of stitches are called wales.

Our team inspects the socks and ensures the product is made with the correct fibers, is constructed correctly, and meets or exceeds our standards for sizing, length, cross stretch, and quality parameters. After the socks are knit, we ensure the toe seams are closed. Some of our knitting machines also include a seaming operation. However, many of our socks move along to the next process: seaming

After its first quality inspection, the sock goes to the seaming area. Here the toe opening is closed.

The process is based on two simple quality factors: the quality of the seam itself and the comfort of the wearer. We also take into account the fibers and the usage of the socks too while deciding the appropriate seaming process.

We use machinery specifically designed for sock seaming. Our seaming operators align the socks in this machine for seaming. The socks are usually kept inside out for this process. The clip is a special knit area where the seam will be sown. The clip also has extra fabric that must be removed for a comfortable toe seam. The machine then turns the sock right side out as the final step. Now the sock looks like a sock and is all set for the next step.

The process has many steps. Here, the socks are washed and dried after the knitting and seaming steps. Washing removes knitting oils and residue from yarns. It allows for adding softeners and conditioners for a soft feel. The “feel” of a sock is called its “hand.” Drying helps “set” certain fibers and treatments, and can help add bulk to some socks.

Colored socks are either dyed after knitting or knit with previously dyed yarn. This already dyed yarn is called in-grain yarn. By using in-grain yarns, many vibrant color blends and combinations are possible. Of course, through all this, we use sustainable methods and organic treatment processes.

Now the socks are ready for the fourth step.

There are three steps in this activity: boarding, pairing, and a comprehensive quality review.

In boarding, the socks are pulled on flat metal foot forms. The forms are dictated by the desired shape and size of the socks. The socks on the forms are steam pressed between two heated surfaces. This gives the sock its finished look.

The freshly boarded socks are then paired. Even socks knit with the same yarns, same machines and the same settings will vary slightly. The pairing process matches socks to other socks with the same slight size variation.

Now we come to the last phase of the quality program: the board/pair operation. Here, we look at quality issues found at board / pair and are traced back through the manufacturing procedure to the source, documented and corrected. We look for missed stitches, holes in seams, or any flaws in the fabric in the sock.

Once the socks are boarded and paired, the next step is packaging. The paired socks are either sent to the packaging line for immediate shipment or to fill future orders. Our packaging is driven by requirements of our retail store customers. Bar coding and standardization are inventory practices for many of our customers. We use shrink wrap. This cuts down shipping costs. And as there is less shipping material to discard, it allows for time, material, and labor savings.