This time we spoke with Nishio Sock Factory in Ono City, Hyogo Prefecture, the manufacturer of ZEROFIT socks.
We interviewed him about socks made in Japan.
Nishio's hobby is the Super Cub, and just inside the factory entrance there was a Cub decorated with lots of stickers.
As you enter the factory, filled with the unique, nostalgic smell of knitting machines and yarn, you will hear multiple knitting machines rattling around in operation.
Every now and then a finished sock will pop out through the tube.
We interviewed Nishio surrounded by sock knitting machines that work tirelessly without a break.
Nishio-san speaks in a relaxed and calm manner.
- ●
- First, please tell us the year your company was founded.
- ●
- "My parents founded the sock factory 35 years ago, and I've been working here for about 30 years. I now support the factory as its president."
- ●
- "Can you tell me about the features of Nishio socks?"
- ●
- "Our main products are pile fabric knitting machines, and we offer machines that prioritize functionality over speed."
- ●
- "I've heard that terry cloth is often used for towels, but what exactly is it?"
- ●
- "Pile knitting is not a matter of the yarn used, but rather the knitting method. In addition to pile knitting, there are other knitting methods such as regular flat knitting and mesh knitting, which allows air to pass through easily. Pile knitting is done by placing the yarn on top of a part called a sinker, which fluffs it up before knitting. For this reason, more than twice as much yarn is used compared to flat knitting. Also, if you increase the rotation speed of the machine itself, the yarn becomes disordered, so it takes more than twice as long to knit."
- ●
- What is mesh knitting like?
- ●
- "On the other hand, the amount of thread used is reduced, but the thread needs to be carefully selected. If the thread is not strong, it will tear."
- ●
- "I see. By the way, is there any loss of socks?"
- ●
- "It depends on the climate, temperature and humidity, but we lose about one in every 20 to 30 pieces. When you handle the thread, dust inevitably comes out, and if the dust gets tangled in the thread, it will be scrapped. It's a delicate job."
On the left are the sinkers of a knitting machine and on the right are the needles (two types of each). These are the tools needed to knit socks.
- ●
- "What is the difference between socks made in Japan and those made overseas?"
- ●
- "I think it's the careful inspection and the creativity. When you want to make socks with a particular touch, it can be hard to convey the fine details overseas, but in Japan, they can handle even the most delicate designs. Another great thing is that they can handle small lots."
A sock knitting machine currently producing tricolor ZEROFIT socks. The dark red area on the right is the pile knitting area.
*The needle and sinker are arranged in a circle.
Nishio-san has a wealth of knowledge about Japanese knitting machines.
Recently, it seems that the number of technicians who can do pile knitting is decreasing.
- ●
- "Our ZEROFIT socks are also made in this factory. What do you think?"
- ●
- "I think these are good socks. In many cases, manufacturers only specify the material and do not specify functionality, but at ZEROFIT, we do not compromise on functionality or small details, so I think we are able to make the socks we want to make. Your company is very particular, and to be honest, it can be difficult to make all sorts of requests, but as sock-making professionals, we are able to make suggestions without hesitation."
- ●
- " ZEROFIT socks have a 'shock absorbing pad' with pile knitting on the heel to reduce shock, an 'air ventilation function' with mesh and flat knitting to create a rugged surface for breathability and massage, 'separate arch support' with elastic yarn that stretches like rubber to tighten the arch of the foot, and a 'graduated compression design' from the ankle to the calf. The complex ZEROFIT socks are made using a variety of knitting methods and types of yarn."
- ●
- "That's right. Compared to socks made with regular flat knitting, we can make about half the number of ZEROFIT socks in a day."
- ●
- "Heat Love socks * are popular when it gets cold, how about these?"
- ●
- "Compared to other companies' products, we use thicker thread, which is also difficult to make... but it's warmer. It's hard work for the makers, but I think it's a great product for customers."
*Heat Love socks are currently out of stock. They are currently in the process of being released for sale this fall and winter.
ZEROFIT socks are made with a complex combination of pile knit, mesh knit, flat knit, and elastic knit.
- ●
- " ZEROFIT socks could only have been made by a team of sportswear developers and sock craftsmen."
- ●
- "That's right. When ZEROFIT socks are displayed in the store, they tend to be functional and look inferior to socks with a more stylish design. That's why customers tend to choose socks that look good. But when they try them on, the less attractive ones turn out to be more functional. ZEROFIT socks were not well received at first, but as more people started wearing them, they started to be bought again and again, and now many people love them."
- ●
- "What do you think makes a good pair of socks?"
- ●
- "I think these are socks that you'll want to wear again. Once you've worn them, you'll feel like you can't wear anything else... That's what makes a good sock."
Thank you for taking the time to do this interview today.
Nishio Socks is run by three people: Mr. Nishio, himself, and his parents. However, Mr. Nishio's sock factory does not have a successor.
In order to ensure that this factory and these socks continue to exist, all we can do is continue to spread the word about the quality of Made in Japan socks.
In fact, ZEROFIT socks are popular even within the company. When you look at people's feet, you'll see that they are all wearing ZEROFIT socks. I am one of those people.
On days when you'll be walking a lot or when you're out walking, wearing ZEROFIT socks will help you feel more positive about walking.
Nishio Socks is run by Nishio himself and his parents.
bonus
The toe part of the socks is sewn by hand.
The mother hand-finishes each sock one by one. She places the socks in the sewing machine and makes one full revolution, resulting in a neatly sewn pair of socks.
The resulting waste materials. I thought it might be possible to reuse them, so I asked, and it turns out they can be connected and woven together like rubber bands to make mats, crocheted dolls, etc. They are provided to cultural centers, where students can enjoy making things by hand.
I also received a cushion for my office chair.
The toes are sewn on by hand, one by one, by the mother.
Recycle the scrap material from the sewn edges.
Cushions made from recycled materials. The earth colors are soothing.
Introducing new antibacterial socks!
1,980 yen (tax included) *Set of 2 pairs
If you're new to functional socks, why not give these a try?
Compared to Zero Fit socks, these socks do not have heel cushioning and have less arch support and ventilation, but they are cheaper in price.
It is ideal not only for sports but also for everyday use.
Click here for details
Classic Zero Fit socks
"Nano Hybrid" adds toe grip functionality to Zero Fit socks