Quality

Sock Factory Tolerance Sheet: Size, Weight and Color

Published: 2026-07-02By ZheSock TeamReading time: 5 min

A sock tolerance sheet is the control page for size, pair weight, color, construction, and packing. It gives the factory a target and gives the buyer an inspection rule. Without it, a 1.5 cm foot length drift, a 3 g weight loss per pair, or one mixed dye lot can become a payment dispute. Write the sheet before bulk yarn is bought. Attach it to the purchase order. Use the same version at inline QC and final inspection.

Table of Contents

1. What belongs on a sock tolerance sheet?
2. Set size tolerance by sock type
3. Control weight in grams per pair
4. Write color rules before dyeing
5. Use AQL and inline checkpoints
6. Put the sheet into the purchase order

What belongs on a sock tolerance sheet?

A useful sock tolerance sheet fits on one page. It should list style number, size range, yarn blend, machine gauge, needle count, approved sample weight, approved sample date, color reference, packing method, inspection level, and the person who approved the standard.

For machine detail, write the actual cylinder data. Common setups are 96N or 108N for thick terry sports socks, 144N for casual cotton socks, 168N for finer crew socks, and 200N for thin dress socks. A 108N terry sock cannot hold the same size tolerance as a 200N dress sock.

Use grams per pair for finished socks. GSM is not the main control number because a sock is tubular and shaped. If the order includes a separate knit fabric part, pouch, or label material, add GSM for that item, such as 180 to 220 GSM for a cotton rib insert. Do not replace pair weight with GSM.

Set size tolerance by sock type

Measure finished socks after washing, drying, boarding, and 24 hours of relaxation. Measure flat on a table. Do not pull the sock unless the sock tolerance sheet states stretched measurement. Write the ruler start point in the sheet because factories may measure from different points.

Adult crew, 144N to 168N: foot length plus or minus 1.0 cm, leg height plus or minus 1.0 cm, welt width flat plus or minus 0.5 cm.
Adult terry sport, 96N to 108N: foot length plus or minus 1.5 cm, leg height plus or minus 1.5 cm, welt width flat plus or minus 0.7 cm.
Thin dress sock, 168N to 200N: foot length plus or minus 0.8 cm, leg height plus or minus 1.0 cm, welt width flat plus or minus 0.5 cm.
Kids sock: foot length plus or minus 0.7 cm to 1.0 cm, based on the size. A baby sock with an 11 cm foot should not use a 1.5 cm allowance.

Compression socks need another standard. Flat length is not enough. Add ankle and calf pressure targets in mmHg, plus the test method and sample size.

Control weight in grams per pair

Pair weight controls yarn cost and wear life. A sample at 36 g per pair and bulk production at 32 g is not a small change. It is an 11.1 percent drop. The sock will feel thinner even if the photo looks close.

For standard cotton blend casual socks, set pair weight at plus or minus 5 percent from the approved sample. For heavy terry socks, plus or minus 7 percent is more realistic because loop height and washing shrinkage change the number. For a 40 g terry pair, plus or minus 7 percent means 37.2 g to 42.8 g.

Weigh at least 10 pairs for an inline check and 20 pairs for final inspection on orders above 3,000 pairs. Pull pairs from different bundles and sizes. Do not weigh only the top pair in one carton. Carton weight is not a product weight check because polybags, tags, carton board, and moisture change the result.

Price checks should match the weight target. As a broad FOB China range, basic cotton ankle socks often run US$0.45 to US$1.20 per pair at 1,000 pairs per color. Terry sports socks often run US$0.90 to US$2.20. Compression socks often run US$1.60 to US$3.80. Yarn blend, needle count, logo work, and packing can move the price outside those ranges.

Write color rules before dyeing

Color control starts before bulk knitting. Approve lab dips or dyed yarn cards, then keep one sealed standard at the factory and one with the buyer. Pantone TCX is useful for design, but it is not enough for final approval because yarn twist and knit texture change the shade.

For solid dyed yarn, many retail programs use Delta E 1.0 to 1.5 under D65 light. Regular promotional orders often use Delta E 1.5 to 2.0. For melange, recycled, or space dyed yarn, visual approval against the sealed sample is often more practical than one spectrophotometer number.

Check body, heel, toe, and welt as separate areas.
Reject mixed dye lots in one retail pack unless the buyer approves them in writing.
Check color before packing. Sorting after carton sealing wastes time.
Record the light source, such as D65, TL84, or CWF, on the inspection report.

For GOTS or GRS orders, confirm the certified yarn source before bulk yarn purchase. For OEKO-TEX material claims, confirm the yarn or material document before production starts.

Use AQL and inline checkpoints

A tolerance sheet needs a sampling rule. For export socks, many buyers use ISO 2859 style sampling with general inspection level II, AQL 2.5 for major defects, AQL 4.0 for minor defects, and zero acceptance for critical defects.

For a 5,000 pair order, general level II often gives a 200 pair final inspection sample. At AQL 2.5, accept 10 major defects and reject at 11. At AQL 4.0, accept 14 minor defects and reject at 15. Critical defects, such as sharp metal, mold, wrong fiber claim, or a safety issue, should be rejected at one piece.

Small orders need a higher check ratio. For a 100 pair MOQ trial, inspect 20 to 30 pairs because one bad bundle can affect the full order. For a 300 pair order, check at least 50 pairs across all sizes and colors.

After knitting: check needle holes, wrong logo position, terry loop height, and size before washing.
After toe closing: check linking ridge, loose yarn, missed stitches, and toe shape.
After washing: check shrinkage, twist, stain, and pair weight.
Before boarding: check size again and sort clear defects.
Before carton sealing: check barcode, pair count, hangtag, polybag, and carton mark.

Put the sheet into the purchase order

The purchase order should name the sock tolerance sheet version and approval date. A clear line is: Bulk goods must follow Sock Tolerance Sheet V2, approved on 12 May 2026, measured after washing, boarding, and 24 hours of relaxation.

State the remedy before production. If average pair weight is more than 5 percent below the approved sample, the factory must sort, remake, or agree to a price adjustment before shipment. If color is outside the approved Delta E range or sealed sample, the buyer may reject the affected dye lot. If size failure is found inline, production should stop until machine tension, washing time, or boarding form size is corrected.

MOQ and timing should also be written in the order file. A practical trial MOQ is often 100 to 300 pairs for available yarn and simple artwork. Custom dyed yarn or jacquard logos usually need 500 to 1,200 pairs per color. Normal export lead time is often 15 to 25 days after yarn and sample approval. Custom jacquard, yarn dyeing, or GOTS cotton orders often need 25 to 40 days.

Frequently Asked Questions

What is the normal size tolerance for adult socks?

For adult crew socks, use plus or minus 1.0 cm for foot length and leg height after washing, boarding, and 24 hours of relaxation. Thick terry sports socks often need plus or minus 1.5 cm. Thin dress socks on 168N to 200N machines can often use plus or minus 0.8 cm for foot length.

Should sock weight be checked before or after washing?

Check sock weight after washing, drying, boarding, and relaxation. Raw knitted socks can contain knitting oil and extra moisture. Write the approved sample weight in grams per pair, then set a limit such as plus or minus 5 percent for standard cotton blend socks or plus or minus 7 percent for thick terry socks.

Is Pantone enough for sock color approval?

No. Pantone helps at the design stage, but final approval should use lab dips, approved bulk yarn, and a sealed production sample. For solid colors, add a Delta E target under D65 light. Use 1.0 to 1.5 for stricter retail work and 1.5 to 2.0 for regular promotional orders.

What AQL level should be used for sock inspection?

A common sock AQL inspection setup is general inspection level II, AQL 2.5 for major defects, AQL 4.0 for minor defects, and zero acceptance for critical defects. For a 5,000 pair order, this often means a 200 pair sample. Reject at 11 major defects or 15 minor defects.

What should importers ask before approving a sock tolerance sheet?

Ask for machine gauge, needle count, yarn blend, approved sample weight, size measurement method, washing process, boarding temperature, color approval method, and final AQL plan. When the order needs compliance documents, ask for the relevant OEKO-TEX, BSCI, Sedex, ISO 9001, GOTS, GRS, or CE files before bulk production.

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