Sock Manufacturer & Exporter | Fibre Information | Men's Socks | Casual Socks | Ladies Socks | Children's Socks
© 2006 The Bangkok Nylon Public Company Ltd. All rights reserved
Manufacturing Process
Stages:
1. Raw Materials
We use a wide selection of yarns specified by our customers and their requirements. The yarn used determines the character of the sock; stretch, sweat absorbency, luster, warmth, etc. We dye nylon on site at our factory, and we source our pre-dyed yarns from top quality suppliers, of which 90% are Thailand based companies. This ensures that we do not have any delays due to overseas supply delays, and guarantees the quality as we can visit our sources easily and regularly.
View our fibre list »
2. Knitting
The knitting machine needles are mounted on a single cylinder (for plain socks) or a double cylinder (for ribbed socks). As the cylinder turns, the needles interlock loops of yarn, beginning at the top and working towards the toe.
Double Cylinders
(from 96n to 220n)
Single Cylinders
(From 108n to 220n)
Our modern machines are able to produce a multitude of styles, and incorporate a range of designs and colours dependent on our customers’ specified requirements. Our products portfolio gives a sample of the many styles that we can produce. To ensure our socks meet our customers’ requirements, we check the size and weight specifications at this stage. We do this using a nahm board if suitable, measuring tapes, accurately calibrated scales, and with a weighted, spring-action stretching machine.
3. Linking – Different Links
Once the sock has been knitted, the toe remains open. This stage is where the toe seam (gore) is created. We can link the socks using either hand linking, sometimes known as the seamless link, or automated linking.
4. Quality Control
Our attentive QC staff check the socks for any defects such as missed stitches, holes in the seams or any flaws in the fabric of the sock. Any problem that is recurrent is reported to the line manager for investigation into the cause.
5. Embroidery
Our embroidery section uses Rayon 120/2, primarily, to create unique embroidered logos on our socks for a number our domestic and international customers. Our high performance embroidery team can embroider approximately 24,000 dozen pairs per month with logos, emblems or made-to-order-patterns
6. Finishing
The final process in the manufacture of our socks includes many different aspects which come together to finally complete a commercial item. These are:
a. Setting – Steam
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 when we ensure that the two socks we put together match perfectly. With certain yarns there can be slight discrepancies in size, even from the same consignment. This process eliminates the chances of two socks of slightly differing size being put together. Also, this stage is used for quality control.
c. Packing
The socks themselves are only part of what sells; our customers have many different requirements when it comes to the presentation of their product. The packaging we can use for the products may consist of labels, bands, hangers, hang tags, riders, promotional stickers, UPC stickers or anything else that our customer requires. We use Thai companies to produce the labels, etc in order to reduce costs and delays caused by shipping; unless, of course, our customer would prefer us to import them from their current supplier.
d. Metal detector (twice)
We use two detectors once the product is complete to ensure that no shards of metal are present in the socks. This can happen if needles break during knitting. This is a rarity; however, for the benefit and safety of our clients and their consumers, we feel this is a necessary step.
e. Quality Control
The quality of our products is assured through continuous checking and monitoring throughout the manufacturing process. The final stage before boxing and shipping is where our quality supervisors check the final product to ensure it meets our clients and our own exacting standards.
f. Boxing
Our finished products are boxed and kept secure; we have undergone checks by some customers regarding the United State’s C-TPAT regulations, so we have reviewed and modified our procedures to ensure our compliance. Our shipping agent shall then forward the goods to the Port and to the freight forwarder of our customers’ choice. This is typically done on a FOB basis.