Jeans Production And Quality Process

The pair of jeans that you buy from the store has a very long history

, and quite a unique production process. The particular quality of cloth that denim is made of was originally used to make sails. Today's jeans may come in a variety of styles and colours, but it is still made from the same raw material: cotton. There are polyester blends and 2% spandex in case of stretch denims, but 100% cotton forms the majority of jeans produced, and blue, the most popular colour.

Whether it is mens jeans or womens jeans, the quality ultimately depends upon the cotton from which it is made. The raw cotton is put through a carding machine to disentangle it into threads called slivers which are finally rolled into yarn. Unlike most fabrics, denim is coloured when it is still in the form of balls of yarn. Each ball is dipped multiple times in the dye. Denim was originally coloured blue from organic Indigo. For almost a century now, synthetic Indigo is being used in its place. When you wash a normal pair of blue jeans, the colour fades off in layers because of the way it was dyed.

Since cotton cultivation uses up an enormous amount of water, certain environmentalists are working on creating jeans from hemp. Some companies are now introducing recycled lines. The chemicals and dyes used in the production of jeans are usually biodegradable, but if dumped into water bodies (especially the starch that is used to strengthen the cotton threads), will, in the process, consume oxygen precious to aquatic life forms. Companies that manufacture jeans are expected by law to have their own waste disposal units. Some of them also have machines that can calculate the exact amount of fresh dye required. This ensures that a spent mixture can be reused by adding the optimum quantity of dye to it.

The yarn is woven in automated looms, the cloth is rolled into bundles and transferred to the manufacturing unit where the jeans that we see in stores are created. Ten to fifteen separate pieces of denim are required to make a standard pair of jeans. The number of pieces is not determined by whether it is womens jeans or mens jeans that is being tailored, but on the brand and its trademark design. A hundred sheets of denim are cut at once by machine from patterns shaped out of cardboard or paper.

After this, the pieces are stitched by manually operated industrial sewing machines and each pair of jeans is put together by hand. The finishing stage simply involves brushing the jeans clean and getting them machine ironed, and packed into crates.

When buying jeans, you might want to find out whether the denim is raw or if it has been sanforized (pre-shrunk). Sanforization (pre-shrunk) denim ensures a shrinkage between 1% and 3%, and up to the third wash only. Raw denim, on the other hand, will shrink at least by 10% on the initial wash alone. Some connoisseurs prefer the experience, and buy only raw denim to customize the shrink and fit to suit their personal style.

Find out how we can help you to get your perfectsmart jeans, whether it is womens jeans, mens jeans or childrens jeans, please visit www.smartjeans.co.uk.

by: Lawerence Claycamp

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