How denim fabrics are made
Summary
TLDRThis script details the meticulous process of creating high-quality denim for jeans. It starts with blending cotton from global fields to ensure fiber length consistency, crucial for denim toughness. The cotton undergoes purification, combing, and twisting into strong threads, often combined with elastane for stretch. The iconic indigo dyeing process is highlighted, where threads are repeatedly dipped and oxidized to achieve the signature blue. The script also explains the twill weaving pattern and introduces 'Salvage' weaving on vintage looms for a softer, more durable fabric. Finally, it touches on the post-weaving processes like softening, shrinking, and strict quality control to maintain consistent denim quality for brands like Jack and Jones.
Takeaways
- 🌎 Cotton is sourced from fields worldwide.
- 📏 The length of cotton fibers determines the toughness of denim fabric.
- 🔄 Cotton from different bales is blended to ensure consistent quality.
- 🧹 Impurities such as seeds and weeds are filtered out of the cotton.
- 🧵 The cleaned cotton fibers are combed and formed into a thick rope called a sliver.
- 💪 Six slivers are combined to create a stronger, slimmer sliver which is then twisted into a strong thread.
- 🔧 Elastane is twisted into the thread to create stretch denim with stretchability.
- 🌿 Most jeans are dyed with indigo, an ancient dye originating from the indigofera plant.
- 🔵 Threads are repeatedly dipped in indigo dye to achieve an intense dark blue color, with the inside remaining white, giving denim its characteristic look.
- 🔍 The twill pattern of blue and white threads creates the denim pattern, with the warp threads running vertically and weft threads running horizontally.
- ⚙️ Salvage denim, made on old shuttle looms, is softer and more durable, produced primarily in Japan and Italy.
- 🛠 The denim fabric is softened, stretched, heated, and shrunk to ensure jeans remain the same size after sale.
- 🔍 Strict quality control is performed to detect defects or color variations before the fabric leaves the mill, ensuring consistent quality for Jack and Jones jeans.
Q & A
What determines the toughness of denim fabric?
-The toughness of denim fabric is determined by the length of the cotton fibers used in its production.
Why is it necessary to blend cotton from different bales?
-Blending cotton from different bales ensures consistent quality by minimizing variations in fiber length.
What impurities are removed from the cotton fibers during the blending process?
-Impurities such as seeds and weeds are filtered out during the blending process to ensure the purity of the cotton fibers.
What is a sliver in the context of cotton processing?
-A sliver is a thick rope of combed and blended cotton fibers that is formed before spinning into thread.
How is the cotton sliver made stronger in the production process?
-The cotton sliver is made stronger by stretching and combining six slivers to create a single, stronger yet slimmer sliver.
What material is added to the cotton thread to create stretch denim?
-Elastane, a kind of rubber, is twisted into the cotton thread to create a thread with stretching ability for stretch denim.
What is the characteristic color of most jeans and how is it achieved?
-Most jeans are colored in the characteristic blue indigo color, which is achieved by dipping the threads in large tubs with indigo dye and exposing them to oxygen, which turns the threads blue.
What is the twill pattern of blue and white threads in denim called and how is it created?
-The twill pattern is created by the blue warp threads being pulled up and down on the loom and the white weft threads being shot back and forth, resulting in a pattern of blue and white threads.
What is the most common weave used in denim production and what does it signify?
-The most common weave used in denim production is a three by one weave, meaning that three warp threads are visible for every weft thread, making the weft more visible on the back side of the fabric.
What is Salvage and how is it different from modern denim weaving?
-Salvage is a type of weaving used in the RDD collection, made on old shuttle looms dating back to the 1950s. It is slower and creates a softer, more durable fabric with less tension on the yarn, requiring more skilled workers and is only produced in Japan and Italy.
Why is the denim heated and shrunk before it leaves the fabric mill?
-The denim is heated and shrunk to prevent the fabric from twisting after it's sewn into jeans, ensuring that the jeans stay the same size after they are sold.
What is the final step in the denim production process before the fabric leaves the mill?
-The final step in the denim production process is a strict quality control check to detect any defects or variations in color and fabric, ensuring consistent quality denim.
Outlines
🌏 Global Sourcing and Blending of Cotton
This paragraph discusses the global origin of cotton and the importance of fiber length in determining denim toughness. It explains the process of blending cotton to ensure quality consistency, including the removal of impurities and the combing of fibers into a sliver. The paragraph also introduces the concept of combining six slivers to create a stronger, yet slimmer, thread suitable for stretch denim, which incorporates elastane for added flexibility.
📜 The Art of Denim Weaving and Dyeing
The second paragraph delves into the weaving process of denim, highlighting the twill pattern created by the interplay of blue warp and white weft threads on the loom. It describes the common three by one weave and introduces the Salvage weaving technique used in the RDD collection, which is produced on vintage shuttle looms for a softer and more durable fabric. The paragraph also covers the dyeing process using indigo, sourced from the Indigofera plant, and explains how the characteristic blue color is achieved through a series of dips and oxidation reactions, resulting in the denim's distinctive faded look when worn.
🔍 Quality Control and Fabric Finishing
The final paragraph focuses on the post-weaving processes of denim production. It describes how the fabric is softened, stretched, and heat-treated to prevent twisting and ensure consistent sizing. The paragraph concludes with a discussion on the strict quality control measures in place at the fabric mill, where any defects or color variations are detected to maintain the high standards of denim quality for the Jack and Jones brand.
Mindmap
Keywords
💡Cotton
💡Denim
💡Blending
💡Impurities
💡Sliver
💡Elastane
💡Dyeing
💡Indigo
💡Twill Pattern
💡Weave
💡Salvage Weaving
💡Quality Control
Highlights
Cotton comes from fields all over the world.
The length of the cotton fibers determines the toughness of the denim fabric.
To ensure consistent quality, cotton is blended by scraping layers off each bale and drawing them into the mixer.
Impurities such as seeds and weeds are filtered out to obtain pure blended cotton fibers.
The pure cotton fibers are combed and poured into a thick rope called a sliver.
Six cotton slivers are stretched and combined to create a stronger yet slimmer sliver.
The sliver is pulled and twisted into a strong thread.
For stretch denim, elastane (a kind of rubber) is twisted into the thread, providing stretchability.
The threads are collected on large barrels to prepare for dyeing.
Most jeans are colored with the characteristic blue indigo dye.
Indigo dye originates from the indigofera plant and is among the oldest dyes used for textile dyeing.
Threads are dipped in large tubs of indigo color and exposed to oxygen to turn blue.
The repeated dipping creates an intense dark blue color with a white core, giving denim its characteristic faded look when worn.
Denim's twill pattern consists of blue (warp) and white (weft) threads woven together.
The most common weave is a three-by-one pattern, where three warp threads are visible for every weft thread.
Salvage denim is made on old shuttle looms from the 1950s, producing a softer and more durable fabric.
Salvage denim production is slower and requires skilled workers, primarily in Japan and Italy.
To prevent fabric twisting, denim is softened, stretched, heated, and shrunk.
Strict quality control detects any defects or variations in color to ensure consistent quality.
Consistent quality denim is essential to maintain Jack and Jones' standards in jeans.
Transcripts
the route cotton comes from fields all
over the world the length of the cotton
fibers determines the toughness of the
denim fabric however the length of the
fibers is different from one bale to
another so to ensure consistent quality
that cotton is blended the layer scraped
off each Bale and drawn into the mixer
here all impurities such as seeds and
weeds are filtered out the pure blended
cotton fibers are then combed and poured
into a thick rope called a sliver now
the cotton is clean and consistent but
not very strong six cotton slivers are
stretched and combined creating one
stronger yet slimmer sliver this sliver
is then pulled and twisted into a strong
thread
for stretch denim elastane which is a
kind of rubber is twisted into the
thread creating a thread with stretching
ability the threads are collected on
large barrels to prepare it for dyeing
[Music]
most jeans is colored in the
characteristic blue indigo color indigo
is among the oldest dyes used for
textile dyeing and originates from the
indigo Ferrer plant the threads are
dipped in large tubs with indigo color
and pulled up in the air on large drums
when the indigo reacts with the oxygen
it turns blue the threads are dipped
repeatedly until the cotton threads has
an intense dark blue color the color
creates a coating around the thread the
thread is still white inside giving
denim its characteristic faded white
look when worn
[Music]
if you look closely at your own pair of
jeans you can see the twill pattern of
blue and white threads the blue threads
called the warp is pulled up and down on
the loom and a white thread called the
weft is shot back and forth from the
entire length of the loom creating the
denim pattern
the most common weave is a three by one
meaning that three warp threads are
visible for every weft thread that is
why the weft is more visible on the back
side of the fabric
[Music]
another type of weaving is Salvage used
in our RDD collection salvaged denim is
made the original way on old shuttle
looms dating back to the 1950s the
production speed is much slower than
modern looms reducing the tension on the
yarn creating a softer feel and and more
durable fabric these old looms requires
more skilled workers and is only
produced in Japan and Italy because of
their long tradition and jeans
manufacturing
[Music]
to prevent the fabric from twisting
after it's sewn into jeans its softened
and stretched the denim is also heated
and shrunk to make sure the jeans stay
the same size after it's sold before the
denim leave the fabric mill it undergoes
a strict quality control here any
defects or variations of color and the
fabric is detected at consistent quality
denim is necessary to ensure that Jack
and Jones quality in jeans
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