SOCK MANUFACTURING PROCESS
STAGE
01
Crafting Your Perfect Socks
STAGE
02
Designing Your Ideal Pair
STAGE
03
Approval Time
STAGE
04
Sample On the Way
STAGE
05
Pattern Coding
STAGE
06
Yarn Selection
STAGE
07
The Art of Dyeing
STAGE
08
Knitting Process
STAGE
09
Initial Inspection
STAGE
10
Sewing & Linking
STAGE
11
Second Inspection
STAGE
12
Boarding
STAGE
13
Pairing, Labeling & Final Check
STAGE
14
Shipment
Designing Your Perfect Sock
An incomplete or incorrect brief can negatively affect the entire sock production process. That’s why we ensure the process starts with accurate, detailed information. Our experienced production team connects with you to understand your business needs in depth—reviewing design specifications, preferred patterns, yarn selection, and machine requirements. After collecting the necessary details, we conduct an in-depth analysis and develop a custom manufacturing plan tailored to you.
Finalizing Your Sock Design
In this phase, we finalize your sock designs and patterns while ensuring alignment with your brand vision. Labels, packaging, and hang tags are also prepared. You can choose from our existing design library, request a custom design, or submit your own artwork. For labeling and hang tags, you may use your own brand or opt for ready-to-go options from Bonami Sock Factory.
Final Approval Stage
We have carefully reviewed your requirements and offered the best possible options. Now it’s time to finalize your order! Please let us know if there are any last-minute changes to the sock design. You can also confirm the order quantity, material composition, and sizing to help us move forward with production without delay.
Your Sample Is On the Way!
Once all details are confirmed, we move quickly into the sample production phase. For custom designs, samples are usually ready within one week. Standard “quality samples” are provided free of charge, while custom samples may involve production and shipping costs. These samples are created to let you preview the final product with full accuracy.
Pattern Coding
We convert your dream design into a language that our knitting machines understand—coding! Our technical team programs your sock design into our machines with precision, ensuring flawless execution at every stage. Once pattern coding is complete, the machines are set, and your design begins to come to life.
Yarn Selection
We use only high-quality yarns for our socks. Our blends typically include 80% pure cotton for softness and breathability, and 20% technical fibers with 50% Lycra for added durability. This combination ensures superior comfort and elasticity in every pair of socks we produce.
The Art of Dyeing
Once your ideal yarn is selected, we move on to dyeing and coloration. You can pick from our standard color palette or request a custom color. Our expert dyeing team uses Pantone color matching to deliver the exact shade you're looking for—ensuring consistency and vibrancy.
Sock Knitting Process
Once the yarns and patterns are loaded into the knitting machines, production begins and your socks start taking shape. With our state-of-the-art knitting machines, yarns are woven precisely according to the approved patterns. Every stitch is crafted with care to ensure durability and comfort. At the end of this stage, what began as yarn transforms into high-quality socks ready for the next step.
Initial Quality Control
Time for quality control! The first batch of socks off the production line is thoroughly inspected by our experienced QC team. Every pair is carefully examined—from seams to structure. Any detected issues are corrected immediately to ensure seamless progress throughout the production cycle.
Linking & Toe Closing
The toe linking process is carried out by automated machines, continuously monitored by our trained staff. While the machines handle stitching with precision, our team watches closely to catch any defects. This guarantees every pair of socks meets our premium quality standards.
Second Quality Inspection
Quality above all! In the final stages of production, socks go through a second round of quality checks. Our QC team ensures every detail—fit, stitching, and style—matches your expectations. We don’t overlook a single detail when delivering excellence.
Boarding (Shaping)
The boarding stage involves heat-pressing and shaping the socks to give them a final, polished form. Socks are steamed and molded under specific temperature and pressure, making them neat, professional, and ready for use.
Pairing, Labeling & Final Check
In this final stage of production, socks are carefully paired and go through one last round of inspection. Each pair is labeled and packaged based on branding and customer instructions. Your socks are now fully prepared for shipment.
Shipping
In the final step, all orders are securely packed and delivered straight to your warehouse or the address you’ve provided. No matter where in the world you are, your shipment arrives safely—right at your doorstep.
