Manufacturing Process

Manufacturing

Made in Nara, Japan

Nara Prefecture is Japan’s top sock-producing region.

01. Customer feedback and planning

Thanks to people like you, we have many repeat customers and can design new products to resolve our customers’ issues according to their feedback. Each year, we create five to ten new items.

02. Yarn selection

TGUTS-MAN socks use up to five types of yarn. ・Front yarn in a range of natural and synthetic fibers such as cotton, silk, wool, hemp, and nylon, which determine the socks’ texture ・Back yarn for elasticity; usually nylon, polyester, or polyurethane ・Elastic yarn used for compression and to keep the socks from slipping down ・Functional yarn, as needed, for patterning or to eliminate odors In addition, the yarns used in GUTS-MAN socks are specially selected for their various characteristics, such as thickness, strength and elasticity.

03. Knitting

Thanks to people like you, we have many repeat customers and can design new products to resolve our customers’ issues according to their feedback. Each year, we create five to ten new items.

04. Sewing

The sewing process is done manually. For example, we cut the tube-shaped portion of the sock and connect it to the foot portion, and we sew the elastic opening around the calf to the inner portion of the sock cuff. Each sock is carefully hand-sewn by craftsmen with over 30 years of experience, a process that began before GUTS-MAN was even established as a brand and continues to this very day.

05. Testing

We conduct compression tests, wear tests, breathability tests, and odor tests on our socks. An inspection agency has confirmed the results of our wear test: our Super Strong Five Toe Socks can withstand wear and tear at levels six times stronger than what is required of regular sports socks.

06. Embroidery

When logos or other patterns are required, our socks go through an embroidering process. We use a 20-needle embroidery machine that can finish a sock with overwhelming speed.

07. finishing

Each sock is fitted onto a sock-shaped aluminum plate and steam treated. This treatment ensures that all knit parts of the socks are of uniform size.

08. Printing

Products with a non-slip surface go through non-slip processing. Our craftsmen apply silicon coating to each individual sock by hand and treat the socks with steam.

09. Inspection,processing and needle detection

Inspections at each stage, including the final inspection, are all conducted by hand. Each sock is promptly and carefully checked for fraying, holes, thread ends, and overlapping stitches before packaging. All our products pass through a needle detector. Quality and safety are our highest priorities.

10. Shipping

We provide same-day shipping for both domestic and overseas online orders. In addition, in every shipment we enclose Tatsumi Tsushin, our regular newsletter packed with information about the company, which also asks our customers for their impressions, opinions, and any issues they would like to see addressed. We reference this feedback when developing new products. Finally, we double check the packaging of each order before official shipping.