Making Tabio's Products
Product Planning
- Research / POS Data
- We are constantly doing research to gather information on a variety of fronts, and use POS (point of sale) data to stay abreast of market trends like popular colors.
- Planning Meeting
- Our planning is based on the information we gather.
- Design
- Every aspect of each product is carefully evaluated, from the design and raw materials onward.
- Planning Meeting
- A second meeting follows the evaluation stage, where we confirm our design and materials plans.
- Samples
- Next, we make actual samples to check for any unforeseen image or quality issues.
- Quality Inspections
- We inspect every detail for quality, looking for ways we might be able to improve a product even more.
- Internal Product Preview
- Sales department and shop personnel meet with people from other areas of the company for another round of evaluation of each sample product from every angle. Here we like to imagine how a product will perform on store shelves.
- Manufacturing
- We test-market samples at selected shops. Only those products that prove appealing to our customers move on from this stage to actual manufacturing.
- Distribution
- The products that have passed all these reviews are finally distributed to the shops.
- Data
- We collect data directly from all the shops to quickly get a handle on any need for additional colors, quantity adjustments or more products.
Manufacturing
Raw Yarns / Dyeing
There are two types of dyeing: “yarn dyeing,” where the raw yarns are dyed first, and “piece dyeing,” where the final product is dyed. Yarn dyeing is generally reserved for luxury products.
Knitting
Knitting is the primary process by which socks are made. Yarns and synthetic fibers are extremely sensitive to temperature and humidity, and these conditions must be carefully controlled.
Separation
Knit socks are made in long tubes, which are then cut or melted at the points that form toe and elastic opening to produce individual socks.
Turning Inside Out / Checking for Damage and Dirt
The just separated socks are still open at the toe. Each one is turned inside out to seam this opening, and checked at the same time for any damage or dirt.
Rosso Versus Linking
There are two ways to seam the toe. In the “Rosso” method, the toe is stitched in a single line, while in the “Linking” method the toe is stitched one loop at a time. The linking method produces socks that are free of lumps or pilling and fit the feet perfectly without any sloppy feeling.
Finishing
A metal plate is inserted into the socks to “iron” them for a better appearance.
Pairing
The socks are then matched into pairs.
Packing
The pairs of socks are clipped together with a packer.
Folding
Joined pairs of socks are folded at the heel.
Printing
The trade name is stamped on the sole.
Stickers
Stickers listing the size and materials are added.
Tagging
A tag specifying the quality, size, and handling procedures is attached to each pair of socks.
Inspection
The socks pass through an inspection machine to ensure that there are no pieces of metal.
Packaging
Every pair of socks is individually packaged and placed in a box containing ten pairs.
Quality Testing
Wash Fastness Test
Socks are tested for discoloring in the wash.
Light-fast Color Test
Socks are tested for discoloring due to light.
Friction Test
Socks are tested for discoloring due to moisture (sweat).
Bursting Test
Socks are tested for resistance to local pressure.
Abrasion Test
Socks are tested for resistance to abrasion from the inside of the shoe.
Pilling Resistance Test
Socks are tested for (wool) pilling.
The Ideal Pair of Socks
Socks must withstand the harshest use conditions of any textile product.
The average pressure applied to the heel is equivalent to 1.8 times the body’s full weight, and a pair of socks must be able to withstand the powerful friction this generates. Socks function also both as underwear and fashion items. We strive to make the perfect pair of socks: a “second skin” that holds up under tough conditions yet feels so good you forget you are wearing them.
A Special Frame of Mind
A pair of socks is destined to undergo extreme hardship.
It goes without saying that the professionals who work in this industry practice their craft with meticulous, loving dedication.
This commitment contributes to a pleasant workplace filled with congenial colleagues, where we cheerfully give our all to ensuring that the entire production process, from the selection of materials to the shipment of the final product, proceeds with the greatest of care.
