06 Basic Guidelines for Denim Jeans Manufacturing

06 Basic Guidelines for Denim Jeans Manufacturing

The history of denim jeans started in 19th century at America. The Levi Strauss and Jacob Devis were the main key persons and founder of denim jeans pant. The Levi Strauss came from Germany to US in 1853 where he joined his brother’s dry goods business. He was dealing in different items in which cotton fabric was also included. Whereas, the Jacob W. Davis (a tailor of different items like tents, horse blankets, and wagon covers) was one of his customer of cotton fabric. One day, Jacob Devis customer ordered him a stardy pant that could bear hard work. So, he bought denim-jeans fabric from Levi Strauss and made stardy pant with copper-rivets at different parts of the pant.

After making the first successful development in jeans, the Jacob decided to do continue this line with some more advancement. So, he contacted the Levi Strauss and asked him to join him for this project. The Levi Strauss agreed to support him for this development and then they started work on denim jeans garments. So, this is how the first jeans pant was invented in 1873 with the joint efforts of Jacob Devis and Levi Strauss. And after that their jeans factory introduced and changed the main concept of jeans pant. And it’s the tireless efforts of both experts which introduced the denim jeans from workwear to fashion wear.

History of Denim Jeans Fabric:

As we all know that the jeans are made from denim. The word denim is derived from sturdy fabric called “Serge de Nîmes” in French language. The weavers of Nîmes in Italy were trying to reproduce the cotton corduroy fabric but due to some error they developed a sturdy twill fabric known as denim. And this twill fabric’s weft passes through two or three warp threads. Initially, the warp thread was indigo blue dyed whereas the weft threads remained in white color. So, the facing part of the fabric was blue whereas the reverse side of the denim fabric was in white color.

Although with the passage of time, there are too much enhancements in the characteristics and look of the denim fabric. But, the regular denim jeans fabric still has the same look (reverse side white and front side blue indigo). The blue indigo is a dye which was initially made from trees. But with the passage of time, it is now making with synthetic chemicals with some advance look and features. There are mainly four types of denim fabrics which are usually extensively use in denim jeans fashion industry. The main denim jeans fabrics are cotton/stretch, poly cotton stretch, 100% cotton and poly cotton. Although there are some other types too in denim yet they are not as hot selling items as above said qualities.

Denim Jeans Garment Making Process:

After having a basic information about denim jeans history, making and types of denim. Let’s have a look on below step by step detail of denim jeans pant making process. And for this we will start the same from development process from fabric development to garment finishing step:

Spinning & Weaving:

The cotton denim jeans fabric is developed by cotton thread which is made from cotton crop. The field workers picked the crop from fields and send it to spinning mills for yarn development. The spinning mills follow the sequence of processes that convert raw cotton fibres into yarn. And by following these numbers of spinning processes, they get clean, strong, uniform yarns required for weaving process. After going through rope dyeing and sizing process, the yarn sized beams are ready for weaving. This yarn is used both in warp and weft thread of the denim to develop a stable and long lasting fabric. After weaving process, the fabric is moved to finishing department for final finish/look.

Cutting:

At cutting, first of all, the required garment (top/bottom) patterns are made before cutting start. And these patterns are drawn on cutting layers on denim fabric. Cutting layers length and thickness (05/200 layers per cutting table) are decided according to the requirement of order. Once the layers are done, the plotter machine drawn the paper pattern which is laid on the denim layers for cutting. The sharp cutters are used to cut these layers according to the drawings.

Stitching:

The cut parts of denim fabrics layers are then move to stitching department for stitching purposes. In some garments, the embroidery or printing is required. So, these parts normally move to embroidery or printing department before stitching process. The stitching of normal pant is done by polyester/cotton thread (top thread: 30-40 count, inner thread: 50-100 count). And normally the stitching process is done in chain production system (garment stitching operations divided into number of operators). Once, the stitching is done then raw top/bottom moved to washing process.

Washing:

The washing process is divided into two steps, the first one is dry process and the other one is wet process. In dry process, all the before wash effects like distressing, sand blasting, tie & dye, pintuck effects etc. are done before the washing process. After completing the dry process the garment steps into enzyme/stone wash process. During this process, the shade and grain effects are matching through different enzymes and bleaching chemicals. The white used effect at front and back is normally made with KMNO4 (Potassium permanganate) chemical. If the wrinkles are required on garment then the garment wrinkles are cure into oven after washing process.

Finishing:

After washing, the garments are landed on finishing department. Here, all pre-finishing (cropping, buttoning, mending etc.) and finishing (pressing, quality, tagging & packing etc) processes are done. Once quality is done then garments are packed into cartons according to the required client’s ratio for final dispatch.

Some Ending But Important Points:  

The above fabric and garments making process is a conventional process. Although there are so many enhancements are already made in the above process but the basic procedure is still same. If someone wants to closely understand the denim jeans making process then he/she must go through the above steps first. After having a complete know how about the conventional method. Then he/she should review the other modern steps which are mostly related to environment sustainability in garment manufacturing process.

As it’s really necessary to know these sustainable technologies enhancement too. Because the old or conventional manufacturing process is not eco-friendly. Although the manufacturing steps remain same in new method yet the techniques which we adopt in these steps will be changed. For example, the crop cultivation method and spinning method has improved now. As in old cultivation method, we were consuming too much water and chemicals in our fields. Whereas now, the consumptions of water and chemicals are now too much controlled in both cultivation and spinning process.

Same is the case with garments manufacturing. After knowing the above steps, you should know about the lean manufacturing process. As it considers as best manufacturing approach which guides you how to enhance manufacturing with zero waste. The traditional or old washing process was the more water and hazardous chemical consuming process. So, now there are some enhancements in washing process too which  considers as eco-friendly. There are so many technologies which are working perfectly and saving too much water and chemicals. And more importantly, it is saving our land from the toxic chemicals of washing and finishing process of garments.

Author: admin

Fakhar is a textile professional with more than 15 years of experience in the fields of Marketing, Merchandising, Sourcing, Liaison, Training & Development, Industrial Relations. Being a keen observer, he constantly tracks the textile innovations and other notable events. And whatever he thinks, is interesting and informative, share the same along with his own understanding and opinion. He loves book reading, cricket and chess.

2,315 thoughts on “06 Basic Guidelines for Denim Jeans Manufacturing”

  249. เคล็ดลับ บริการ รับทำ seo ราคา SEO 2021 ยังไง ให้ติดหน้าแรก
    หากคุณคือนักการตลาด ต้องเข้าใจคำว่า SEO (Search Engine Optimization) หรือการปรับปรุงเว็บไซต์เพื่อให้ปรากฏในอันดับต้นๆ ของ Search Engine เพราะ SEO คือสิ่งที่ช่วยเพิ่มปริมาณคนเข้าเว็บไซต์ สร้างความประทับใจแก่กลุ่มเป้าหมาย
    เพราะว่าผลตอบแทนจากการทำ SEO
    แล้วอันดับดีขึ้นช่างหอมหวาน SEO จึงเป็นเหมือนเกมที่มีการแข่งขันอย่างเข้มข้น ไม่ใช่ทุกคนจะสมหวัง หลายเว็บไซต์ทำ SEO แต่ล้มเลิก
    เนื่องจากไม่สามารถต่อสู้กับเว็บไซต์ที่มีความเชี่ยวชาญเรื่อง
    SEO และเงินทุนที่มากกว่าได้
    การทำ seo คืออะไร ผมจะบอกแบบเข้าใจง่ายๆ คือ การผลักดันเว็บไซต์ตัวเองให้ติดหน้าแรกเวลาค้นหาบน google ด้วยkeywordที่ต้องการ ซึ่งจริงๆแล้ว คำนี้ย่อมาจากคำภาษาอังกฤษว่า Search engine optimization

    Reply

  266. Simply want to say your article is as astonishing.

    The clarity in your post is simply cool and i can assume you are an expert on this subject.
    Well with your permission allow me to grab your RSS feed to keep updated
    with forthcoming post. Thanks a million and please keep up the gratifying work.

    Reply

  267. I am really impressed with your writing skills as well as
    with the layout on your weblog. Is this a paid theme or did you modify it yourself?
    Either way keep up the excellent quality writing, it is rare to see a nice blog like this one today.

    Reply

  271. Very good blog! Do you have any suggestions for aspiring writers?
    I’m planning to start my own site soon but I’m a little lost on everything.
    Would you recommend starting with a free platform
    like WordPress or go for a paid option? There are so many choices out there
    that I’m completely overwhelmed .. Any suggestions?
    Thanks a lot!

    Reply

  282. My partner and I stumbled over here by a different web address and thought I
    might as well check things out. I like what I see so i am
    just following you. Look forward to going over your web page repeatedly.

    Reply

  283. I really love your website.. Great colors & theme. Did you make this amazing site yourself?
    Please reply back as I’m attempting to create my own personal website and would love to
    know where you got this from or exactly what the theme is called.
    Thank you!

    Reply

  289. Good day! This is my first comment here so I just wanted
    to give a quick shout out and say I genuinely enjoy reading through your articles.

    Can you suggest any other blogs/websites/forums that
    cover the same topics? Many thanks!

    Reply

  290. I do agree with all the ideas you have introduced to your post.

    They are really convincing and will definitely
    work. Still, the posts are very short for starters.
    May just you please lengthen them a bit from next time?
    Thanks for the post.

    Reply

  291. Excellent goods from you, man. I’ve understand your stuff previous
    to and you are just extremely excellent. I really like what you have acquired here,
    really like what you’re saying and the way in which you say it.
    You make it entertaining and you still care for to keep it wise.
    I can’t wait to read much more from you. This is actually a terrific web site.

    Reply

  292. A motivating discussion is worth comment. There’s
    no doubt that that you need to publish more on this
    subject, it may not be a taboo matter but typically people don’t speak about these subjects.
    To the next! Best wishes!!

    Reply

  293. After looking at a handful of the blog posts on your website, I seriously like your way of blogging.
    I saved it to my bookmark webpage list and will be checking back soon. Please visit my website as well and let me
    know how you feel.

    Reply

  294. Hello there, just became aware of your blog through Google, and found
    that it’s truly informative. I’m going to watch out for
    brussels. I’ll be grateful if you continue this in future.
    A lot of people will be benefited from your writing.

    Cheers!

    Reply

  295. Woah! I’m really digging the template/theme
    of this blog. It’s simple, yet effective. A lot of times it’s difficult to get that “perfect balance” between usability and
    visual appearance. I must say you’ve done a awesome job with this.
    In addition, the blog loads very quick for me on Safari. Exceptional Blog!

    Reply

  297. We are a bunch of volunteers and opening a brand new scheme in our community.
    Your site provided us with useful information to work on. You’ve done a formidable job and our whole community will probably be thankful to you.

    Reply

  298. Have you ever thought about creating an e-book or guest
    authoring on other blogs? I have a blog based on the
    same information you discuss and would really like to have you share some
    stories/information. I know my subscribers would appreciate your work.

    If you are even remotely interested, feel free to shoot me an e-mail.

    Reply

  1443. Necesita urgentemente un préstamo hipotecario o un gran préstamo de inversión, consulte nuestras listas de todas las ofertas de préstamos.

    Reply

  1480. I intended to compose you a bit of note in order to give many thanks again about the awesome basics you’ve contributed above. It’s generous of people like you giving easily all a few individuals could have advertised as an e book to end up making some dough for themselves, most importantly given that you could possibly have done it if you ever decided. These pointers as well served like the fantastic way to fully grasp other people have similar eagerness like my own to know lots more on the topic of this issue. I am certain there are millions of more fun opportunities in the future for individuals who looked at your blog post.

    Reply

  1676. My husband and i felt absolutely ecstatic Edward could conclude his inquiry from your ideas he discovered from your very own site. It’s not at all simplistic just to be giving for free hints that men and women have been making money from. And we all do know we have the website owner to be grateful to because of that. Most of the explanations you’ve made, the easy site menu, the friendships you can assist to engender – it’s everything exceptional, and it’s assisting our son and our family do think that content is cool, and that is extremely important. Many thanks for all the pieces!

    Reply