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How do you make custom socks?
Socks are very important to us, to show how much care and passion our socks are made, I write this blog. Here I will explain which steps are taken to achieve the fantastic end product that is for sale with us. In addition, we would like to show that we work together with our manufacturer to achieve a fair product for fair prices.
The design process
The first step in the production process is to convert the design we have made to a low resolution format. Depending on the quality of the sock that is ordered, the machine used to make the sock is chosen. Our more expensive socks have 200 stitches all around, the cheaper ones 160. Each stitch can have a different color. In order to achieve an optimal design, the number of pixels of the designs are therefore reduced (!!!) to the lowest possible quality with 160 or 200 pixels around the sock.
Setting up the machine
The correct yarn is then connected to the machine at the machine that will make the sock and the design is loaded onto the machine. From then on, trial socks are made and small adjustments are made per sock to achieve a perfect sock. When 1 perfect sock has come out of the machine, the machine can start running at full speed.
Quality and error control
A machine can never run independently. The machines regularly get stuck or a needle breaks, causing a sock with something wrong with it. A red lamp will then light up on the machine. In the factory, people continuously walk past all machines (about 40) to check what is wrong and fix problems. When a needle is broken, it is also checked whether the last socks produced are still good.
Ironing the socks
When 100 socks are ordered, about 10-15% more are always scheduled on the machine. This is because there is a chance that there is a 15% loss due to the above causes. When the machine stops, the errors are taken out and the correct ones counted. On some machines the toes of the sock are still open. These are then sewn together piece by piece with other machines. With the latest machines, the toes are already together and the socks go straight through in trays to a carousel with a kind of flat iron in the shape of a cut leg. The socks are put on this leg and ironed from the inside so that they can be neatly packed flat.
When the socks are nicely ironed, they are neatly packed in pairs in the way that is desired. There are various options such as our dealer packaging, our banderole, or a plastic bag. The barcodes are also stuck on the packaging here.
After all this has been done, the socks are packed in boxes, labeled and shipped to our warehouse in the Netherlands. Upon arrival in the Netherlands, we check the socks again to see if this is as expected. We always keep 1 sample behind so that we always know what we have made. This can be useful for reorders or customer inquiries. After that, the socks are stored in our department store to be sold through the site, or shipped to the customer, or delivered to retailers / or distributors.