Denim blue jeans manufacturing process

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photo credit: playbuzz.com

Denim blue jeans manufacturing process

If anyone was to go through your clothing drawers right now they would ultimately find one thing inside every person’s clothing collection: Jeans. Jeans have become a standard in the clothing world due to their quality. Jeans are generally made from denim and are held on a pedestal due to their strength and also a level of comfort. This type of clothing has been worn by everyone from sailors out at sea to miners inside the earth. They are a sturdiest of work pants yet still a fashionable piece of clothing used in designs by the biggest designer brands. We all know what jeans are yet most have no idea how they are made.

This entire operation starts with denim. Denim has been used for hundreds of years and although some parts of it have changed it is essentially the same idea. Denim originally was crafted with the use of wool. It then moved to being formed with a combination of cotton and wool. However, the blue jeans of today are now manufactured by using solely cotton.

The cotton is what gives denim its unrivaled comfort. Another crucial part of the identity of blue jeans is the blue color. This blue color was once applied by creating a dye from the widely used indigo plant however with changes in technology they now have created a synthetic indigo dye.

In order to make blue jeans, you have to begin with two steps: carding and spinning. With the process of carding, the cotton is put inside of a machine that contains bent wire brushes. These bent wire brushes will clean, detangle, straighten, and gather all of the cotton threads into tiny slivers. When these slivers are combined together they are moved to a spinning machine that will turn stretch out then twist the cotton slivers, forming a spool of yarn. After all the cotton slivers have been spun into a yarn they are ready to be moved to the dying stage of blue jeans manufacturing. This step is different than most other products as the yarn for blue jeans is dyed before it is weaved into a product.

photo: wikipedia

A ball warp, a large ball of yarn, is then dipped into a vat containing the synthetic indigo dye mixture. This process is done multiple times in order to create layers of color on the yarn. These different layers of dying are precisely why your jeans fade a little every time you wash them. After the yarn has been successfully dyed it is then moved onto what is known as slashing. Slashing is coating the yarn with a sizing agent to create stronger and stiffer threads. After this has been completed the yarn is now ready to be woven into pieces of denim.

The yarn is put onto mechanical looms and woven. The newly woven denim cloth is not cut into patterns which are then sewn together in a specific fashion to create the jeans you wear. Generally, all the cutting is completed with the aid of high-speed cutting machines. This allows extremely accurate pattern cuts to ensure uniform jeans every time. The sewing of the jeans is usually done in an assembly-line with the aid of human-operated sewing machine. This allows for absolute perfection as human eyes can ensure that the jeans are being pieced together properly.