The influence of setting temperature on sock size

In today's global sock market, international wholesale buyers have strict requirements for the quality and dimensional stability of socks. As a key process parameter in the sock production process, setting temperature plays a vital role in the dimensional stability of socks. This article will explore the relationship between setting temperature and sock size, analyze the performance of socks of different materials at different setting temperatures, and how to meet the needs of international wholesale buyers by optimizing the setting process.

I. The principle of the influence of setting temperature on sock size
(I) Basic concept of heat setting
Heat setting is a process of rearranging and crystallizing the fiber molecular chains of socks under specific temperature, humidity, tension and time conditions, so that the size and shape of the socks are stabilized. In this process, temperature is a key factor affecting the movement and structural changes of fiber molecules.
(II) The relationship between temperature and fiber shrinkage
When socks are subjected to external forces during the production process, the fiber molecular chains will undergo a certain degree of displacement and deformation. At the setting temperature, the fiber molecules obtain enough energy to overcome internal resistance and readjust to a more stable position. If the setting temperature is too low, the fiber molecular chain has limited mobility and cannot be fully adjusted and fixed, which makes the socks prone to shrinkage and deformation during subsequent use. On the contrary, too high a setting temperature may cause the fiber molecular chain to relax excessively, or even destroy the internal structure of the fiber, affecting the strength and dimensional stability of the socks.

2. Setting temperature and dimensional stability of socks of different materials

(I) Cotton socks
The main component of cotton fiber is cellulose, and its molecular chain structure is relatively regular. Cotton socks are usually set at a temperature of 150-160°C. Within this temperature range, cotton fibers can better maintain their original crystalline structure, while eliminating the internal stress generated during the production process, so that the dimensional stability of the socks is improved. If the setting temperature is lower than 150°C, the shrinkage rate of cotton socks may be relatively high, especially after washing, deformation and shrinkage are prone to occur. When the setting temperature exceeds 160°C, the strength of the cotton fiber may decrease, affecting the durability of the socks.
(II) Polyester socks
Polyester fibers have high crystallinity and orientation, and their molecular chain structure is relatively tight. Polyester socks are generally shaped at a temperature of 170-200°C. As the shaping temperature increases, the dimensional thermal stability of polyester fibers gradually increases. Polyester socks shaped at 170°C can still maintain good dimensional stability when used in an environment of 150°C. However, when the shaping temperature exceeds 200°C, although the dimensional thermal stability continues to improve, the improvement effect is not significant, and it may have a certain impact on the color and feel of the polyester fiber.
(III) Nylon Socks
Nylon fiber has good molecular chain flexibility and its glass transition temperature is relatively low. The shaping temperature of nylon socks is usually between 160-180°C. Within this temperature range, nylon fibers can effectively adjust and rearrange their molecular chains, significantly improving the dimensional stability of socks. If the setting temperature is lower than 160°C, the dimensional stability of nylon socks is poor and they are prone to stretching and deformation during use. When the setting temperature is higher than 180°C, it may cause excessive shrinkage of nylon fibers, resulting in smaller socks and affecting wearing comfort.

3. Case analysis of the actual impact of setting temperature on the dimensional stability of socks
(I) Case 1: When a sock factory produced a batch of cotton socks, the setting temperature was set to 140°C
In subsequent quality inspections, it was found that the shrinkage rate of this batch of socks was high and the dimensional stability was not ideal. After adjusting the setting temperature to 155°C, the shrinkage rate of the cotton socks produced during washing and daily use was significantly reduced, and the dimensional stability was significantly improved, meeting the quality requirements of international wholesale buyers.
(II) Case 2: Polyester sports socks produced by a certain brand, with a setting temperature of 180°C
In actual use, consumers reported that the socks can still maintain a good size and shape after multiple washes, thanks to the appropriate setting temperature that ensures the dimensional thermal stability of polyester fibers. However, when another supplier raised the setting temperature of polyester socks to 210°C, although the dimensional stability was slightly improved, the color of the socks became dull and the feel became hard, affecting the market competitiveness of the product.
(III) Case 3: Nylon socks produced by a certain company, with a setting temperature of 150°C
In the quality inspection, it was found that the size deviation of the socks was large and they were easily stretched and deformed. After adjusting the setting temperature to 170°C, the dimensional stability of nylon socks was significantly improved, and the dimensional deviation was controlled within a reasonable range, meeting the strict standards of international wholesale buyers.

4. Other factors affecting the effect of setting temperature on sock size
(I) Setting time
The setting time and setting temperature are interrelated and jointly affect the dimensional stability of socks. Generally speaking, if the setting time is too short, even if the setting temperature is appropriate, the fiber molecular chain cannot be fully adjusted and fixed, resulting in poor dimensional stability. If the setting time is too long, the fiber molecular chain may be overly relaxed or aged, which will also affect the size and performance of the socks. Under different sock materials and setting temperature conditions, it is necessary to determine the appropriate setting time. For example, the setting time of cotton socks at a temperature of 150-160°C is usually 30-60 seconds; the setting time of polyester socks at a temperature of 170-200°C is generally 20-40 seconds.
(II) Setting humidity
Humidity also plays an important role in the setting process of socks. Appropriate humidity can make the fiber molecular chain softer, which is conducive to the adjustment and rearrangement of the molecular chain, thereby improving the setting effect. For some fibers with good hygroscopicity, such as cotton fibers, certain humidity conditions need to be controlled during setting. Generally, a relative humidity of about 80%-90% is more suitable. As for synthetic fibers such as polyester and nylon, due to their poor hygroscopicity, the humidity requirements during the shaping process are relatively low, but appropriate humidity can still help improve dimensional stability.
(III) Shaping tension
Tension control is also important in the shaping process of socks. During the shaping process, too much or too little tension on the socks will affect their dimensional stability. If the tension is too high, the sock fibers may be overstretched, making the socks larger in size and prone to loosening and deformation during subsequent use; if the tension is too low, the socks cannot maintain a good shape and size, and wrinkles and shrinkage may occur. Generally speaking, during the shaping process, the warp tension of the socks should be properly controlled so that the socks can fit smoothly on the shaping mold, and the weft tension should be uniform and moderate to ensure the dimensional stability and appearance quality of the socks.

5. How to optimize the shaping process to improve the dimensional stability of socks
(I) Accurate temperature control
In order to ensure the temperature accuracy of the sock shaping, high-precision temperature sensors and advanced temperature control systems should be used to monitor and accurately control the temperature of the shaping equipment in real time. At the same time, the temperature sensor is calibrated regularly to ensure the accuracy of temperature measurement. During the production process, the shaping temperature is set strictly in accordance with the process standards according to the material and quality requirements of the socks, and fine-tuned according to the actual situation to avoid the impact of temperature fluctuations on the dimensional stability of the socks.
(II) Reasonable combination of process parameters
Determine the best combination of process parameters such as shaping temperature, time, humidity, tension, etc. according to the material, style and quality requirements of the socks. Through a large number of experiments and data analysis, a shaping process parameter database for socks of different materials is established to provide a scientific basis for production. In actual production, appropriate adjustments and optimizations are made according to the specific conditions of different batches of socks to ensure that each batch of socks can achieve good dimensional stability.
(III) Selection and maintenance of shaping equipment
Selecting shaping equipment suitable for production needs is the key to improving the dimensional stability of socks. Advanced shaping equipment usually has better temperature control accuracy, uniformity and stability, which can ensure that the socks are subjected to uniform and consistent heat during the shaping process. At the same time, the shaping equipment is regularly maintained and maintained to ensure the normal operation and stable performance of the equipment. Check and clean the heating system, ventilation system and tension control system of the equipment, and replace worn parts in time to ensure the performance and accuracy of the shaping equipment.
(IV) Strict quality inspection and control
Establish a complete quality inspection system and conduct strict size inspection and stability test on the shaped socks. Use advanced inspection equipment and methods, such as fully automatic size measuring instrument, shrinkage tester, etc., to accurately measure and analyze the size deviation, shrinkage rate and other indicators of the socks. For socks that do not meet the quality requirements, rework or adjust the production process in time to ensure that every pair of socks shipped has good size stability and quality. Through statistical analysis of quality data in the production process, continuously optimize and improve the shaping process to improve product quality and stability.

6. The significance of shaping temperature to international wholesale buyers
For international wholesale buyers, the size stability of socks is one of the important factors affecting their purchasing decisions and market sales. Stable size can ensure the quality consistency of socks during transportation, warehousing and sales, and reduce the risk of customer complaints and returns due to size problems. At the same time, socks with good dimensional stability can improve consumer satisfaction and loyalty, and help wholesale buyers establish a good brand image and reputation in the highly competitive international market. In addition, accurate size specifications are also conducive to wholesale buyers to carry out inventory management and sales forecasting, and reduce operating costs and risks.
In cooperation with international wholesale buyers, sock manufacturers should pay full attention to the impact of setting temperature on sock size, and improve product quality and dimensional stability by optimizing the setting process to meet the strict requirements of buyers. At the same time, strengthen communication and cooperation with buyers, understand their specific quality standards and market needs, and jointly promote the development and progress of the sock industry.
In short, setting temperature is one of the key factors affecting the dimensional stability of socks, and socks of different materials perform differently at different setting temperatures. By deeply understanding the relationship between setting temperature and sock size, comprehensively considering other relevant factors, and optimizing the setting process, the dimensional stability of socks can be effectively improved, the needs of international wholesale buyers can be met, and the competitiveness and sustainable development of sock companies in the international market can be promoted.