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We all know and love tights and/or pantyhose, but how many actually know how their favorite garment is made? I decided to write this post for this very reason — to further enhance everyone's understanding of these wonderful garments. The best demonstration I've seen was shown in episode 2 of Discovery Channel's show about the manufacture of common items — How It's Made. Rather than reinvent the wheel, I thought I'd use their segment for this purpose. You can read the transcript for it, as well as watch it below.
Women appreciate that pantyhose come in a variety of colors, sheers, and textures. Us guys, we appreciate them too, maybe for different reasons. Making a nylon stocking takes only a few minutes. However, it's a complex operation that involves the knitting of 5 to 8 threads as fine as a hair. The threads, usually nylon and spandex, stong and elastic, are used. Sometimes, polyester or cotton are added. The knitting machine goes into action. This one fashions a tube for sheer stockings in 90 seconds. In 3 minutes, it makes a tube for tights. The speed is adjusted according to the product being made, varying between 750 and 1200 revolutions per minute. Once the tube is knitted, it is sucked up and lands in a bag where it will be inspected. More than 500 machines share the work, each making a model that is specific for it. The two ends must now be joined. This automated machine assembles the two tubes together to form the pantyhose. Then a scissors cut the pantyhose, a necessary step in the production of a pair. This opening is enlarged to allow for sewing that will join the two tubes at the point of the panty. The label with the size or brand name is already sewn in place in just 10 seconds by this robotic machine. At this pace it sews in 4,800 labels in 8 hours. Installing a gusset requires some preparation. A scissors makes a hole at the joining point. Then the stocking is turned inside-out by suction so that certain stitching can be done on the inside. Thus, these stitches will be less visible. Now the foot must be sewn. This robotic machine places the foot in position. Then the sewing machine makes stitches at the same time that cuts away excess material. This step requires only 10 seconds. Then the pantyhose is turned right-side-out, again using suction. Everything is ready for installation of the gusset. The pantyhose is placed in a tub and taken to this department. The stocking is again suctioned and placed on a gusset machine by the operator. This method ensures that the gusset will be installed well-centered without a pleat. Putting in the gusset is the final operation in the process. A pre-cut piece of cotton is slid into place reserved for the gusset and automatically sewn in. Only aesthetic touches remain, such as adding a little color to the pantyhose. They're placed in this machine, which has as a large drum with 4 compartments and a 45 kg capacity. The pantyhose are washed in soapy water, then immersed in dye. The temperature climbs gradually to 93 degrees celsius. After a 5-minute rinsing cycle, a softener is added. This all takes 2 and a half hours. Once dry, they proceed to inspection. The pantyhose is placed on a form which stretches it to allow for inspecting it for any imperfections. Is all is well, the pantyhose is transferred onto another metal form where it will be pressed. The pantyhose is positioned, guided by a magic eye. The pantyhose is then carried toward a steam room, remaining there for 2 and a half seconds before being dried in 7 and a half seconds at 140 degrees celsius. They fold and pack 420 pantyhose per hour and make 180,000 pairs per day.
Women appreciate that pantyhose come in a variety of colors, sheers, and textures. Us guys, we appreciate them too, maybe for different reasons. Making a nylon stocking takes only a few minutes. However, it's a complex operation that involves the knitting of 5 to 8 threads as fine as a hair. The threads, usually nylon and spandex, stong and elastic, are used. Sometimes, polyester or cotton are added. The knitting machine goes into action. This one fashions a tube for sheer stockings in 90 seconds. In 3 minutes, it makes a tube for tights. The speed is adjusted according to the product being made, varying between 750 and 1200 revolutions per minute. Once the tube is knitted, it is sucked up and lands in a bag where it will be inspected. More than 500 machines share the work, each making a model that is specific for it. The two ends must now be joined. This automated machine assembles the two tubes together to form the pantyhose. Then a scissors cut the pantyhose, a necessary step in the production of a pair. This opening is enlarged to allow for sewing that will join the two tubes at the point of the panty. The label with the size or brand name is already sewn in place in just 10 seconds by this robotic machine. At this pace it sews in 4,800 labels in 8 hours. Installing a gusset requires some preparation. A scissors makes a hole at the joining point. Then the stocking is turned inside-out by suction so that certain stitching can be done on the inside. Thus, these stitches will be less visible. Now the foot must be sewn. This robotic machine places the foot in position. Then the sewing machine makes stitches at the same time that cuts away excess material. This step requires only 10 seconds. Then the pantyhose is turned right-side-out, again using suction. Everything is ready for installation of the gusset. The pantyhose is placed in a tub and taken to this department. The stocking is again suctioned and placed on a gusset machine by the operator. This method ensures that the gusset will be installed well-centered without a pleat. Putting in the gusset is the final operation in the process. A pre-cut piece of cotton is slid into place reserved for the gusset and automatically sewn in. Only aesthetic touches remain, such as adding a little color to the pantyhose. They're placed in this machine, which has as a large drum with 4 compartments and a 45 kg capacity. The pantyhose are washed in soapy water, then immersed in dye. The temperature climbs gradually to 93 degrees celsius. After a 5-minute rinsing cycle, a softener is added. This all takes 2 and a half hours. Once dry, they proceed to inspection. The pantyhose is placed on a form which stretches it to allow for inspecting it for any imperfections. Is all is well, the pantyhose is transferred onto another metal form where it will be pressed. The pantyhose is positioned, guided by a magic eye. The pantyhose is then carried toward a steam room, remaining there for 2 and a half seconds before being dried in 7 and a half seconds at 140 degrees celsius. They fold and pack 420 pantyhose per hour and make 180,000 pairs per day.
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