Nestled between the foothills of the Appalachian Mountains, in the small town of Fort Payne, Alabama, lies a sock mill.
A long, single-lane road leads to the large square metal building known as Zkano (pronounced zee-kano), standing firmly against its backdrop of rolling hills. When you first walk in, you are greeted by a small storefront, displaying a collection of colorful socks ranging in patterns and sizes.
However, it’s beyond this storefront, in the heart of the mill, where the true magic unfolds. Rows of blue knitting machines line the warehouse floor, their mechanical whirring drowning out any other sound as threads weave together. Pallets of vibrant thread line the back wall, displaying hues from soft pastel pink to vibrant chartreuse. Nearby, a bulletin board adorned with notes, reviews, and positive messages reflects the community spirit at Zkano. Here, it’s evident that this isn't merely a place of production for profit—it’s a hub where something unique is being crafted. But how did a sock mill in a small Alabama town come to pioneer socks adorned with modern, trendy patterns?
“It started with my parents." Born in Fort Payne Alabama, Gina Locklear’s family returned to her birthplace in the 1990s to follow a dream; to make socks. At that time, it was a dream held by many, with over half of the residents of Fort Payne employed by the 150 sock mills in the area. In the 1990s, one out of every eight pairs of socks globally was made in Fort Payne.
Being raised in Fort Payne, Gina watched her parents put in the hard work that comes with running a family business. “During the summers, because my sister and I were so young, we had to go up to the mill with my parents. They made socks, seamed socks, and did everything from start to close every day. Even after my mom would finish for the day and take my sister and me home, my dad would stay until midnight. I watched them put in enormous amounts of hard work, dedication, and perseverance, which stuck with me.” It was in these early moments, witnessing her parents’ determination and getting her first experiences in manufacturing that planted the seeds that would eventually become Zkano.
By the mid-2000s, American manufacturing was in a death spiral. “All around us, mills were closing. The one beside us closed, and then the one across the street closed. We were just sitting around waiting for the inevitable. Then we got word from a decade-long customer that they were going to start offshoring their socks, we thought, ‘That's it, "' Gina explains. But instead of the financial turmoil discouraging her, it motivated her to fight for her family’s business. “It lit a fire in me. After watching my mom and dad work so hard over the years and put everything they had into this business. I just wanted to try.”
So instead of jumping ship, Gina dug her heels in and decided to go a completely different route; she started her own brand. And thus, the idea for Zkano was born. However, starting a brand from scratch, was easier said than done, especially on the heels of the 2008 recession. “The wheels had already started turning in 2007, and I’m sure there was pushback at the time," Gina says, laughing. "But I’m a stubborn person, so any pushback went in one ear and out the other. The biggest resistance, however, came from my parents." Even in good times, a sock mill required a significant financial and time commitment. "They just didn’t want to see me waste all that time or money on a business that might not even get off the ground or could close shortly after starting”. But even with the initial resistance from her parents, they eventually got on board. So Gina set off to create Zkano.
Assuming the role of "boss" for the first time posed another significant challenge for Gina. "The hardest part was that, while I knew the manufacturing side and had help from my parents, I didn’t have anyone to guide me on the business side. Figuring out selling and marketing on my own was incredibly tough. I had to navigate things like creating a logo and trademarking the brand, which was completely new to me."
As Zkano approaches its 15th anniversary in October, Gina reflects proudly on the business she’s built. "We're a small team of six, with three members who've been with us since the 90s. It’s fulfilling to know I'm employing people who are deeply rooted in the industry." Despite her pride, being the boss remains challenging. "I wear many hats—from designing to sourcing raw materials—but the toughest part is not having someone to lean on at times. Often, it’s solely up to me to solve problems as they arise."
When creating Zkano socks, Gina had already adopted an organic lifestyle, so she knew she wanted sustainability to be a cornerstone of Zkano as well. “When I started Zkano I knew from the get-go, that if I was going to make socks, I wanted it to be from organic cotton. I wanted to make something that wasn’t putting pesticides into the atmosphere, harming the wildlife and the water system. “
Looking ahead, the future of textiles in America is unclear but also not completely hopeless. “To preserve the textile industry, we have to get young people interested in textiles and how to create them. To work on and fix these machines, you can’t go to school for it, you have to apprentice for a few years to learn how to do that type of work. These are skilled labor positions that aren’t being backfilled by the newer generations, so we have to overcome that to keep the factories and mills open.” While factory work may be going out of style, a new, more promising trend has risen, especially among young people as we see consumers take a more conscious approach to clothing shopping.
“People are becoming passionate about organic cotton, sustainability, things that last for a long time, and just quality items that just don’t go into the landfill.” One report by Morning Consult found in 2023, nearly two-thirds of U.S. consumers said they routinely sought out “Made in America” products over the past year. “When I started, I didn’t know anything about marketing, but I thought if I just told my story, maybe that would get people interested," Gina reflects. "And maybe, on a small, itty bitty scale, we can help manufacturing in the United States by making people aware of it.”
With a small team dedicated to the art of sock-making, Gina continues to defy industry trends and champion American manufacturing. “We see that [support for "Made in America" products] and it is encouraging, just by the emails and reviews we get," Gina smiles. "Our story resonates with people—being a family business, and being Made in America has become super important over the years.”
With each pair of socks crafted from organic cotton, Zkano not only delivers comfort and style but also embodies a legacy of resilience and dedication. As Gina looks to the future, she hopes to inspire a new generation to appreciate the value of sustainable textiles and the craftsmanship behind each product.
Zkano stands as a testament to the appeal of quality, American-made goods, and above all else, the best marketing is a good story.