Socks, the often underappreciated yet essential accessory, have graced the feet of humanity for centuries. From their humble beginnings as mere foot coverings to the fashionable statement pieces they’ve become, socks are a testament to the intersection of comfort, style, and craftsmanship. Let’s walk you through how socks are created in our sock factory in Guangdong, China.
We conducted regular factory visits to check the supplier’s production facilities and learn more about the production process. It also helps us ensure that the production goes smoothly.
Aside from the step-by-step sock production, we will also give tips on choosing the right sock manufacturer/factory for your business. So. let’s delve in!
How Socks are Made: A Step-by-Step Guide
Creating a pair of socks is a complex and fascinating process that involves a series of meticulously executed steps. Each step plays a crucial role in determining the quality, comfort, and design of the final product. Here, we break down the sock manufacturing process into its various stages:
1. Designing Socks
This stage involves creating a blueprint for your socks, including their length, style, and any unique patterns or features. Once the design is forwarded, the next stage will be preparing the raw materials for the socks.
2. Preparing the Raw Materials
After choosing the design, we visited the raw material supplier – the sock factory partner, which specialises in making different types of yarn and dyeing it according to the Pantone colour.
When manufacturing, it is important need to have full control of the upstream supply stream
The production process starts at the laboratory, where specialists calculate the amount of ink/colour that they need to use to match the requested Pantone colour using the computer program.
It is essential to find the right proportion of the chemical substances necessary to keep the colour and prevent it from fading.
The machine in the picture below tests a few combinations to see which one can make the closest Pantone match. Swatches are also made in a small container laboratory to confirm the colour with the client.
3. Dyeing the Yarn
The production hall has more than 20 large and small containers. In order to customize yarn, the minimum order quantity for each Pantone matched yarn is about 50kg, or about 2000 pairs of socks. A big container, like shown below, can dye yarn for nearly 200,000 pairs of socks.
In the image below. Reels with plain yarn are being placed on the special metal construction, which loosens the yarn so the ink can dye every part of the yarn evenly. The crane is placing the construction in the container with a dyeing solution.
After this process, the reels are moved to the next machine. The principle of operation is similar to the centrifuge – the reels are spinning around at a high speed inside the container, which allows them to get rid of the extra water and get dry quicker.
To dry the yarn completely, the reels then go to the next machine. It acts like a big oven and, with high temperature, will quicken the drying process of the reels of yarn. All machines at the factory are automated, and once the drying session is finished, the reels can be moved to the next production hall.
In the picture below you can see how the machines are rewinding the reels using the different shape of the plastic base which is more convenient to use in production.
Once the reels are ready and packed they are being sent to the next factory to manufacture socks.
4. Knitting Socks
On this visit to the sock factory, we checked out the pre-production stage, which is a critically important phase of production. Samples can be remade numerous times to get a perfect product.
Here, the factory is adjusting different specifications to get a good sample and start mass production. And with that, your socks are complete!
Facts About Socks Production
How Do We Choose Our Factory?
Selecting the right sock factory is a pivotal decision that can significantly impact the quality, cost, and success of our sock manufacturing venture. To ensure we find a factory that aligns with our goals and standards, it’s crucial to take several key considerations into account.
Here’s how ODM chose our partner factory!
1. Production Capacity
The first and foremost consideration is the production capacity of the sock factory. Can they handle the volume of socks you require? We determine whether they have the machinery, equipment, and workforce to meet your production needs.
Overcapacity may lead to inefficiencies, while undercapacity can cause delays and compromise quality. The factory’s ability to scale production as our business grows is also essential.
2. Customisation Options
We always ensure that the factory offers customisation as we provide personalised or customised items for our clients. We inquire about its ability to produce custom designs, patterns, and colour variations.
Some factories specialise in the mass production of standard sock designs, while others are more flexible and adept at accommodating unique customisation requests. We always communicate our design and branding needs to ensure they can be met.
3. Quality Control and Assurance
Quality is non-negotiable in the sock manufacturing process. We ask about the factory’s quality control measures and standards. How do they ensure that each pair of socks meets your specifications?
ODM inquired about their quality control processes, inspection points, and whether they conduct random or comprehensive checks during production.
4. Sustainability and Ethical Practices
In today’s conscientious consumer market, sustainability and ethical practices are paramount. We at ODM produce socks made of bamboo. To produce the, we check the factory’s commitment to eco-friendly and ethical manufacturing. Are they using sustainable materials and practices?
Do they treat their workers fairly and uphold ethical labour standards? Look for certifications like OEKO-TEX or Fair Trade that indicate a commitment to responsible manufacturing.
Let’s talk about sustainable bamboo yarn and the top reasons why you’ll love our socks collection in this blog!
5. Communication and Customer Service
Effective communication is the bedrock of a successful partnership with a sock factory. We evaluate their responsiveness and willingness to collaborate. We believe that clear communication can help address any issues, revisions, or concerns promptly.
Likewise, language proficiency and the availability of dedicated customer service representatives can make a significant difference in the manufacturing process.
6. Pricing and Budgeting
Price negotiations and transparency are critical aspects of your partnership with a sock factory. We make sure to understand the cost structure, including manufacturing costs, labour, materials, and any additional fees.
We always make sure to ask about payment terms and shipping costs. A clear understanding of pricing allows us to budget effectively and maintain profitability.
7. Location and Logistics
The factory’s location has a direct impact on shipping costs, lead times, and overall logistics. We consider whether to work with a local factory or collaborate with one in a different location or country.
ODM evaluates the transportation infrastructure and political and economic stability of the factory’s location, as these factors can affect the reliability of your supply chain.
See our sock collection over the years:
Our holiday-themed socks not only bring joy and cheer to your festive celebrations but also prioritize sustainability and safety. Crafted with great care, these socks are made from premium-quality bamboo yarn.
These custom promotional socks come in free or custom sizes according to your target audience. Equipped with antimicrobial technology, these socks can help prevent bacteria that might result in foul-smelling feet and shoes.
Meet Rita, the Water Rabbit. This is our CNY sock in year 2023.
For the Year of the OX, we are proud to support The Christina Noble Children’s Foundation, ODM’s and Mindsparkz ‘s partner charity. See our sock design for year 2020!
In Conclusion
Creating custom-designed socks needs to go through a meticulous process. Moreover, selecting a sock factory is a strategic decision that helps us ensure that we provide quality product needs to our clients.
Here at ODM, we have years of experience in fabricating promotional products. We make sure we connect with reliable factories to provide the needs of our valued partners. Feel free to get in touch and let us assist you in developing some new and innovative ways to promote your brand.
To find out more about production processes in China, be sure to check out our portal on this topic: Manufacturing in China
Meet Dylan, the Wood Dragon
Dragon-design socks are a fantastic way to welcome Chinese New Year! Should you be interested in producing them for your CNY 2024 promotion, feel free to contact our team!
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