medi Guided Tour - From Yarn to Stocking

A virtual guided tour around our stocking production area

Many hands work together at medi to make up compression garments – as is shown here, taking mediven elegance as an example. The production runs as smoothly as clockwork, with the various production stages in each department slotting into each other like cogwheels and showing once again what's behind "Made by medi": real teamwork.

 

 

The "raw materials" arrive: as soon as the yarn arrives, staff look closely at the consignment, inspecting it meticulously: are the goods all in perfect condition? Does the delivery slip tally with the goods? Only then are the goods signed off and entered into the inventory program.

 

All there? Everything OK? After being visually inspected, each box must get a green light before being transported to the knitting hall. Only the very best "ingredients" are approved for stocking production.

 

 

Off to the round knitting hall to transform the yarn into a stocking. The yarn gets threaded into the knitting machine's round knit cylinder, needing a steady hand and plenty of fine motor skills – precision work before the knitting even starts.

 

Four thousand five hundred stitches per second: the speed at which the threads circle the knitting cylinder makes them unrecognisable to the naked eye.

 

6.4 minutes later: the mediven "stocking tube" drops into the hopper; it has an "open toe", which is ready to be finished off. All-round knit stockings start in white. Only after a colour dye will garments get their final appearance.

 

Nine hundred ten thousand eight hundred eighty-eight stitches later, two sample stockings must pass the longitudinal and transverse stretch tests before the machines start making the order in earnest.

 

 

The perfect mesh structure:  Staff pull the stocking lengthwise over the inspection board. A practised eye immediately recognises any irregularity that may have crept into the mesh structure, for example, if the compression yarn ends after 30,000 metres or if the knitting yarn begins to run out after 100,000 metres. 

 

There are no compromises in quality – we reject anything imperfect.

 

Temporary storage: We now deal with the temporary storage of the stockings. The production operating system automatically consigns a storage site until the stockings move to the finishing department for further processing.

 

Closing off the toes: Staff then close off the toes of mediven elegance stockings by eye and hand with a sewing machine, sewing them in a semi-circle form. A steady hand and a great deal of experience are necessary for medi colleagues in this department.

 

 

The next inspection: another inspection phase: Staff pull the mediven elegance over the inspection board and minutely inspect the mesh structure, the heel and the toe.

 

Preparing the topband: Staff use a machine to cut topbands to length and thread the strip into the device based on the size and number of topband sections she needs. The cut edge must be precise and straight for the next production stage.

 

Sewing the topband together: The staff sews the ends of the topband together, matching up the cut edges precisely flush with each other, "binds" the topband, and cuts off even the tiniest loose thread with a pair of sharp scissors to maintain perfection to the smallest detail for mediven elegance.

 

Sewing on the topband: Staff sew the topband exactly edge to edge onto the compression stocking. Because there is no overlap, the transition from the topband to the stocking is inconspicuous – even under tight clothing. The topband seam is now over the back of the leg, precisely in line with the heel. The elastic seam follows the wearer's every movement. Every loose thread – no matter how tiny is carefully snipped off. 

 

 

Handicraft is indispensable here at medi.

 

Making the labels: Staff then make the labels, which include all the stocking details (size, length).

 

Printing the labels: the labels are printed on an endless textile reel and enclosed with the stockings.

 

 

Sewing the labels: Staff feed the row of labels into the special sewing machine, pressing against the label, which is automatically sewn in and cut off. The stocking now has its very own personal "ID card".

 

 

Now to the dyeing and the finishing touch: this is where the mediven elegance stocking becomes colourful. 

 

Off into the dyeing machine: A stack of stockings heads into the dyeing machine, with dye mixtures poured in. The machine is programmed, started, and checked by staff several times during the dyeing process. The running time depends on the colour: pale colours finish sooner than dark shades.

 

 

Environmentally-friendly dyeing: our dyes are harmless with no adverse effects; the runoff can go directly into the wastewater system. The stockings are then washed, dried and laid out. 

 

And yet another inspection: before boxing compression stockings, staff check the length of the stocking and the details on the label.

 

 

Information material: all the information the wearer or patient needs to know is packed in the box, too. The compression stocking is folded and wrapped in tissue paper with information, instructions and medi info.

 

Well packed: the mediven elegance compression stocking has almost reached its target at medi: the new high-quality stocking carton in its medi design. Ready for its first meeting with the patient.

 

 

 

Ready for the long journey: the stocking cartons are first stored in our magenta boxes. The box is covered to protect the cartons. Staff scan the data on the box, with inventory in the operating system automatically updated with stockings stored until ordered.

 

Lightning-fast deliveries: Most orders leave the next working day. Thus, medical retailers, e.g. surgical appliance retailers, can provide their clients with individually measured compression garments within the shortest period.

 

 

A specialist or sales assistant shows the client how easy it is to put the mediven elegance stockings on.

 

 

At long last, on the leg: the stocking is where it belongs now. It gives the patient a feeling of well-being, attracts attention, and guarantees a wow effect.

 

 

 

Many thanks to all our colleagues in medi's production department for their cooperation.