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Brescia - Busi Giovanni has told Knitting Trade Journal how its sock knitting machine technology which is capable of producing innovative, double layer sports socks has been taken up by suppliers to some of the world?s leading sportswear brands.

The Idea Twin Layer machine is based on the same technology as the Brescia-based company?s well established Idea Terry system but also uses the dial needles and a special patented device, which is integrated in the dial itself, to produce the double layer.

Busi customers that have installed banks of the machines include suppliers to sportswear brands such as Puma while

According to Busi export manager Michele Castagna, high quality sports sock manufacturers have been attracted by the Idea Twin Layer?s ability to knit two fabrics at the same time - one inside the other. The external sock is produced in a conventional way by the cylinder needles while the internal sock is knitted by the dial needles.

With this machine, the double layer structure can be extended to the whole of the sock which sees the two fabrics joined at the welt, at the heel and at the toe. This prevents the sliding of the inner layer in respect of the outer layer. It is also possible to knit the socks with a double layer in just a part of the sock, for example only in the sole and in the high-heel.

A further interesting application is creation of pouches inside the socks, which can then be used to hold sports items such as shin-pads attached inside a soccer sock. This means there is no direct contact between the shin guards and the skin, thus avoiding excessive perspiration and unpleasant irritations. In addition, when knitting patterned socks, the yarn ends that normally are inside the sock are ?packed? in between the two layers ensuring increased comfort for the wearer.

Selective double layer

According to Castagna, this provides sock manufacturers with the opportunity to use completely different fibres for the inside of the sock than the outside of the sock, thus opening up new perspectives in the field of technical sport socks. ?This special single-cylinder sock knitting machine, named Twin Layer is capable of knitting two separate and different fabrics, at the same time, on one single sock, joining them only where we want them to be joined,? he said. ?Our system offers the possibility to have the double layer in only certain parts of the sock (only foot or only sole) compared to other machines which are obliged to have a completely double layer sock.

?This machine can also create internal pouches for football socks to host shin guards and has already been used for sports sock production by suppliers to leading sportswear brands such as Puma.?


Optional elements on the Twin Layer system include a device for the production of 3-dimensional patterning and the installation of the company?s latest Rimaglio device for classic linking.

Available in 4 ins diameter, the Twin Layer is available with between 72 and 132 needles and in gauges 24G and 36G.

Knitting possibilities include 1x1 true rib welt, double welt, embroidery patterns in five colours plus the ground as well as embroidery patterns on a mock rib base with four colours per course plus the ground.

Further options include a single feed mesh pattern with an additional five colours per course plus the ground, floated yarn mesh patterns in two feeds, two colour jacquard patterns on a flat knit base and true rib fabric in 1x1, 3x1, 5x1 etc.

The terry device also allows the knitting of sandwich terry and the normal terry in the same sock without any mechanical change. The change from plain stitch to half terry and full terry is carried out automatically.


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