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INTEGRATED TERM PROJECT
SOCKS
By:-
Anshuman (5)Prachi Prakash (12)
Mentor:-
Mr. Shakeel Iqbal
ON
Foundation ProgrammeSemester- II
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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.
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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
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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
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Socks found in Egypt in 12th Century
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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.
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Coptic Socks From Egypt- 1000 AD Socks worn in Europe by Soldiers
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TYPES OF SOCKS
LENGTH PATTERN FIBER
BASED ON
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BASED ON LENGTH
Footies Anklet Crew/Calf Highs
LeggingsStockingsThigh HighOver-knee
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BASED ON PATTERN
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Cotton Wool
Lycra Nylon
Spandex Polyester
BASED ON FIBERS
Common Fibers used are:-
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SPANDEX
ExtremelyElastic
Goodstrength
LYCRA
They aretrademarksofspandex.
Lightweight
POLYESTER
Thermoplastic
Hydrophobic
Good
strength
CHARACTERISTICS
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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.
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KNITTING
It describes the technique of constructing textile
structures by forming a continuous length of yarnsinto columns of vertically intermeshed loops.
Loop Stitch
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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.
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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
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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.
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Weft knitting
Warp knitting
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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
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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
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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
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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.
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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.
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Head/hook
Rivet
Latch
Latch spoon
Butt
Blade/shank
Fig.Latch Needle
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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
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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.
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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.
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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
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Plain knit-front Plain knit-back
Rib structure
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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
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Purl structure Interlock structure
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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.
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Cam and needle
arrangement
Modern knitting machine
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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.
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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.
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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
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MANUFACTURING
PROCESS
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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.
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Raw Materials
Winding of cones
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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.
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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.
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Inspection
Heat Pressing
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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.
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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.
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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.
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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.
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THE INDUSTRY STORE ROOM
KNITTING MACHINE READY FOR IRONING
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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
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BEFORE AND AFTER IRONING USING SOFTWARE FOR PATTERNS
KOREA TEXTILE MACHINERY COLLECTION OF WASTES
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8
3
9
18
30
22
All dimensions in ST(stretch)
Fig. Dimension of the socks
they manufacture.
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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.
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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.
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THANK
YOU