Denim jean models are used by many people today. So, what is the idea behind them? If you are curious about this, you can get answers to the questions you are looking for from our article.
From Cotton to Denim: The Journey of Fabric Creation
Denim jean production starts with the collection of cotton. Cotton from different parts of the world is meticulously collected. The length of the fiber also determines how hard the fabric is. However, its length may vary from one bale to another.
To ensure good quality, cotton is blended, stripped from each bale and drawn into the mixer. Unwanted things such as seeds and weeds are filtered during this process. Then, pure blended cotton fibers are combined.
The pure blended cotton fibers are then combined and poured into a thick rope called a ribbon. Thus, a clean and consistent rope is obtained.
The Role of Weaving in Denim Quality: Exploring Twill and Selvedge
As the denim production process progresses, six cotton strips are stretched. These are combined to obtain a single, strong but thin strip. Then this is pulled and becomes a strong thread. If a flexible structure is desired, elastane is twisted into yarn to obtain a yarn with the ability to stretch.
After this, yarn weaving is started to make denim. During production, blue yarns are pulled up and down, and a white yarn called weft is thrown back and forth along the entire length of the loom. Thus, the denim pattern is obtained.
The most common weaving pattern during the denim manufacturing process is triple-one. In other words, there are three warp yarns against each weft yarn.
Indigo Dyeing Techniques: Traditional vs. Modern Methods
Indigo dyeing plays an important role during the denim manufacturing process. Today, many jeans are known for their characteristic blue color. This color also comes from Indigo. It is one of the oldest plants used for textile dyeing.
During dyeing, the yarns are dipped into large tubs with indigo color, and the indigo is drawn into the air in large drums that turn blue when it comes into contact with oxygen. The yarns are dipped repeatedly until the cotton yarns have an intense dark blue color.
During the denim production process, the color forms a coating around the yarn. The yarn is still white inside, giving the denim a characteristic pale white when worn. However, the dyeing process can sometimes be carried out before weaving.
The Evolution of Denim Manufacturing: From Handcraft to High-Tech
Today, denim jean models can be made in different productions. In some of these, the yarns are first colored and then weaved, while in others, color is given after the production is completed.
Weaving types can also differ due to the effect of advanced technology. The Rescue used in RDD collections is one of them. This is done in the original way on old shuttle looms dating back to the 1950s.
The production speed is slower than modern looms, and by reducing the tension in the yarn, a softer feel and a more durable fabric are obtained. However, old looms also require skill. For this reason, they are especially preferred in Japan and Italy. The denim manufacturing process is softened and stretched to prevent warping when completed. In addition, when the jeans are sold, they are heated and shrunk to keep them the same size.
Sustainability in Denim Production: Innovations and Practices
Denim jean manufacturing is done in many countries today. In this respect, different methods are followed during production in each country. However, in general, advanced methods are used with the advancement of technology.
Moreover, after the denim models are manufactured, a strict quality control is carried out before they leave the factory. In this way, it is understood whether there is a defect or color difference. Thus, it becomes possible to obtain the desired quality.
So, what are the results of all these processes? In this context, there are really many options offered to users. For example, here are some:
- Cotton Denim/100% Cotton Denim
- Raw Denim/Dry Denim
- Cotton Serge Denim
- Colored Denim
- Stretch Denim
- Sanforized Denim
- Washed Denim/Acid Wash Denim
- Gum Denim
- Ramie Cotton Denim
- Reverse Denim
In this respect, many people can find what they are looking for.
