Anshuman, Prachi Socks

8/8/2019 Anshuman, Prachi Socks

1/55

INTEGRATED TERM PROJECT

SOCKS

By:-

Anshuman (5)Prachi Prakash (12)

Mentor:-

Mr. Shakeel Iqbal

ON

Foundation ProgrammeSemester- II


2/55

INTRODUCTION

Socks are a knittedor woven type of hosiery forenclosing the human feet.

Its name originated by shoes

worn by Roman comic actorscalled soccus in Latin.

It was a slipper and fittedloosely so it could be taken

off quickly.


3/55

They are used to-

ease chafing between the foot and footwear.protect footwear by absorbing perspiration anddead skin lost from the foot

provide comfort and tightness

keep the feet warmsoak upsweat, from the foot if sweaty

socks decrease the risk of frostbite in coldenvironments

Today socks are used for both fashionable as well asprotection purposes.

NEED FOR SOCKS


4/55

The word "sock" is derived from the Latin soccus, theOld English socc and the Middle English word socke.

Socks were the first item to be knitted, with the

evidence found from Roman Egypt dating back in 5th

century AD.

8th Century Barbarians wore brightly colored socks.

From about 1340 onwards men started to wear shorter

garments called gippons or pourpoints. This exposedthe leg and required hose that was better supportedand tighter.

HISTORY


5/55

Socks found in Egypt in 12th Century


6/55

HISTORY

By 12th century the word meant a low shoe orslipper and later a knitted foot covering sometimesextending to the knee.

By 1583 the word "stocking" was used to describe acovering for the feet and legs.

Reverend William Lee of England invented a sock-

knitting machine in l589, and started to make hosiery.These socks were easier to produce, cheaper, and

encouraged their popularity.


7/55

Coptic Socks From Egypt- 1000 AD Socks worn in Europe by Soldiers


8/55

TYPES OF SOCKS

LENGTH PATTERN FIBER

BASED ON


9/55

BASED ON LENGTH

Footies Anklet Crew/Calf Highs

LeggingsStockingsThigh HighOver-knee


10/55

BASED ON PATTERN


11/55

Cotton Wool

Lycra Nylon

Spandex Polyester

BASED ON FIBERS

Common Fibers used are:-


12/55


13/55

SPANDEX

ExtremelyElastic

Goodstrength

LYCRA

They aretrademarksofspandex.

Lightweight

POLYESTER

Thermoplastic

Hydrophobic

Good

strength

CHARACTERISTICS


14/55

RAW MATERIALS USED

1) Yarns like cotton, spandex, nylon etc.

2) Water for softening and washing purposes.

3) Electric power for running of knitting machine andprocesses like drying etc.

4) Bunker C-oil is applied on yarns before fed into

knitting machine to help in slipping without friction.

5) Compressed air used to remove minute yarns anddust particles.


15/55

KNITTING

It describes the technique of constructing textile

structures by forming a continuous length of yarnsinto columns of vertically intermeshed loops.

Loop Stitch


16/55

KNITTING

Knitting consists of consecutive loops, called stitches.

As each row progresses, a new loop is pulled

through an existing loop.The active stitches are heldon a needle until another loop can be passed

through them. This process continues on

Knitted garments are often more form-fitting than

woven garments, since their elasticity allows them tofollow the body's curvature closely.


17/55

TERMS USED IN

KNITTINGCourses:- A course ishorizontal row of needle

loops produced by adjacentneedles during knitting cycle.

Wales:- A wale is verticalcolumn of intermeshed

needle loops produced by

same needle at successiveknitting cycles.

Stitch Density:- Total no of

loops in a measured area of

fabric(mostly square inch). Fig. A- Courses B-Wales


18/55

TYPES OF KNITTING

Weft knitting: The wales are perpendicular to the courseof the yarn.

Entire fabric may be produced from a single yarn, byadding stitches to each wale in turn, moving across the

fabric.

Warp knitting:The wales and courses run almost parallel.

One yarn is required for every wale. Since a piece of

knitted fabric may have hundreds of wales, warpknitting is done by machine.


19/55

Weft knitting

Warp knitting


20/55

Flat knitting: Used to make flat, rectangular pieces of

cloth. Done with two straight knitting needles and isworked in rows, horizontal lines of stitches.

Used to knit flat pieces like scarves, blankets etc.

TYPES OF KNITTING


21/55

Circular knitting- Form of knitting that create seamlesstube. Knitting is worked in rounds in a spiral.

Employed to create pieces that are circular or tube-shaped, such as hats, socks and sleeves.

TYPES OF KNITTING


22/55

THE NEEDLE

Needle:- It is a hooked metal needle and is theprincipal knitting element of the machine.

All types of needles must have a method to closethe needle hook to retain the new loop and exclude

the old loop.

Types of needles used:-1) Bearded needle2) Latch needle

3) Compound needle


23/55

BEARDED NEEDLE

1) Stem, around which the needleloop is formed.

2) Head, where the stem is turnedinto a hook to draw the new

loop through the old loop.3) Beard, curved continuation of

hook used to separate thetrapped new loop outside oldloop as it slides.

4) Eye, or groove, cut in stem toreceive the pointed tip of the

beard when pressed, thusenclosing a new loop.

5) Shank, for individual location inthe machine.


24/55

LATCH NEEDLE

The basic knitting action of a latch needle :-

1) Rest position

2) Latch opening

3) Clearing height4) Yarn feeding and latch closing5) Knocking-over and loop length formation.


25/55

Head/hook

Rivet

Latch

Latch spoon

Butt

Blade/shank

Fig.Latch Needle


26/55

They comprise of two

separately controlled parts-open hookand sliding

closing element.

The two parts rise and fall

as a single unit, but at thetop of rise, the hook movesfaster to open the hookand start of the fall of hookdescends faster to close

the hook.

COMPOUND NEEDLE


27/55

KNITTING ACTION

OF NEEDLENeedle is in rest position with previouslyformed loop on its stem and coveredby hook.

Loop is cleared from needle hook to alower position on stem.

New yarn is fed to needle hook at highposition on stem than old loop.

A new loop is formed.

Hook is closed, enclosing new loop and

landing old loop outside closed hook.


28/55


29/55

The new loop is drawn through the headof old loop.

Simultaneously,old loop slides off theclosed hook of needle and is knocked

over.

The old loop now hangs from the feet offully formed new loop.

The same knitting cycle repeats again.

KNITTING ACTION

OF NEEDLE

Expect for the manner of which hook is closed , the

knitting action issimilar for all needles.


30/55

TYPES OF WEFT

KNITTING

Its technical face is smooth,with the side limps of needle

loops having appearance ofcolumns of Vs in wales.

PLAINSTRUCURE

Rib has a vertical chordappearance because theface loop wales tend tomove over and in front ofreverse loop wales.

RIBSTRUTURE


31/55

Plain knit-front Plain knit-back

Rib structure


32/55

It has technical face of plainfabric on both sides, but its

smooth surface cannot bestretched out to reveal thereverse meshed loop wales.

INTERLOC

K

STRUCURE

It has one or more wales whichcontain both face and reverseloops. It can be achieved withdouble-ended latch needlesor rib loop transfer.

PURLSTRUTURE

TYPES OF WEFT

KNITTING


33/55

Purl structure Interlock structure


34/55

KNITTING MACHINE

They are basically Circular knitted machines which are

completely computerized.

Yarns are fed into them through cones.

Designs are made initially on a supporting software

Styler which are then fed into the machine.

Then by using the arrangement of cams and needlesthe machine knits the socks.

The socks which comes out has an open end at the toe.


35/55

Cam and needle

arrangement

Modern knitting machine


36/55

CONSTRUCTION OF

SOCKS

The small diameter of the circular knitting machine

that produce socks impose a limit on their structure so

it is not possible to increase the total size of the socks.

The sock is made at the ankle opening with a welt andrib construction designed to grip the leg.

Modern socks also contain elastomeric threads in therib to aid the grip.


37/55

CONSTRUCTION OF

SOCKSAfter this the rib structure is changed to either plain

fabric or broad rib.

This section is often decorated with jacquard, semi-intarsia, wrap stripe embroidery or structural design.

At the level of the heel the in-step half of the knittedtube is held while knitting is continued on the heel-half

reciprocally.

The length of the course is reduced by one loop on

each side every two courses.


38/55

CONSTRUCTION OF

SOCKSWhen the length of the course is 1/16th of thecircumference of the tube the process is reversed andthe length of the course is increased by one loop on

each side every two courses, picking up the reservedloops in the process.

When the course reaches half the circumference ofthe tube, reciprocal knitting seizes and the spiral of the

tube is recommenced.

The knitting of the foot the toe is generated in thesame manner as the heel pouch


39/55

MANUFACTURING

PROCESS


40/55

MANUFACTURING

PROCESS

Arrival of Raw Materials:- Raw Materials come invarious forms like cheese, cones and pirn.

Winding:- Raw Material is wound into cones and oiled

to allow slipping while knitting.

Knitting:- Socks knitting machine is employed here.

First Inspection:- The knitted piece is checked for flaws.


41/55

Raw Materials

Winding of cones


42/55

MANUFACTURING

PROCESS

Linking:- The toe is linked where there is a open end. Itis done with socks turned inside out.

Second Inspection:- After linking is completed, the

socks with damaged knitting are mended.

Soaping andsoftening:-Soaping is done to remove

oil-stains and dust. The finished socks are soaked indetergent then washed. Then the are put in softeners.

They are soaked for some time then are dried in adrier.


43/55

MANUFACTURING

PROCESS

Setting and Finishing:- Here the socks are heat pressed ina machine after inserting them in a aluminum sheetwhich is of the shape of socks.

Packing:- Socks are then classified by various sizes,patterns, brands etc and are shipped or stored.

This is the complete process of manufacturing.


44/55

Inspection

Heat Pressing


45/55

CARE

Care of socks help to keep the color going, reduce

abrasion, keep it smell-free and thus increases their life.

Various ways for care of socks are:-

Washing:- 1)They should be washed according to the

package instructions.2)They can be hand washed or machine

washed.3)Colors stay longer if washed inside out.

Drying:- Should be dried at low heat or be air dried.


46/55

CARE

Folding:Should be rolled or folded in half. Folding onepair over another shortens the lifespan as

they loose their elasticity.

Wearing:-Feet should be washed before wearing andtoenails should be regularly cut to reduceabrasion.

One should avoid ironing socks as they form beads insome types of fibers.


47/55

CONSUMER SURVEY

The results of survey were-

1) 85% people preferred to use cotton socks.

2) People preferred comfort over other factors.3) People preferred(50%) socks up to Rs. 100 whichmeans that they dont go too much into brands.

4) Most common problems faced were smell and

loosing elasticity.

5) 50% people said that they wear socks for more than6 hours in a day.

6) 40% people said that their socks last for around 6months.


48/55

INDUSTRY VISIT

Company:- Annapurna Knittings, Plot no. 64,Shaktipuram, Prashanti Nagar,

Kukatpally,Hyderabad.

It is a small-scale company with four partners.

Employees:- 15 in total, 10 in manufacturing alone.

They mainly cater local needs and sell their products toschools as uniform socks and also export to retailers inBangalore.


49/55

THE INDUSTRY STORE ROOM

KNITTING MACHINE READY FOR IRONING


50/55

Per day production: 80 dozens

Monthly turnover: Rs. 2 lakhs

Raw materials used: Cotton, Polyester, Spandex, Lycra

Machines used: Circular knitting machine, Compressor,Linking machine, Washing machine, Dryer, Electric iron

The machine used by them are computerized. Thepattern of the socks to be knitted on the machine is

designed via the software Styler 5. The design is fed intothe machine using specially made USBs.

INDUSTRY VISIT


51/55

BEFORE AND AFTER IRONING USING SOFTWARE FOR PATTERNS

KOREA TEXTILE MACHINERY COLLECTION OF WASTES


52/55

8

3

9

18

30

22

All dimensions in ST(stretch)

Fig. Dimension of the socks

they manufacture.


53/55

CONCLUSION

With this project we employed our learning's from subjects:

1) BTM- knitting structure, fibers used.2) SAD- classification based on types and their popularity.

3) GEO-structure of socks, construction.4) POM-industry visit.5) FS-industry visit and depth of study.6) MS-use of materials and machines in socks.7) EOT-functioning of needles, cams etc.


54/55

BIBLIOGRAPHY

Books:-Knitting Technology- David J. SpencerKnitting Clothing Technology- Terry Bracken BuryFiber to Fabric

Websites:-http://www.artisansocks.com/index-socks-by-length.asphttp://en.wikipedia.org/wiki/Sockhttp://www.artisansocks.com/index-socks-by-pattern.asphttp://www.artisansocks.com/index-socks-by-material.asp

Industry Visit:-Annapurna Knittings,Kukatpally - Marketing HeadMr. Rama Raju.


55/55

THANK

YOU

Documents

Anshuman, Prachi Socks