The Detailed Denim Garment Manufacturing Process | 9 Steps

One of the distinctive fashion things that consistently set the pace in today’s fashion is denim clothes. As a result, many individuals will undoubtedly be curious about the denim garment manufacturing process. This Dugarco essay will go into further detail regarding this fascinating denim clothing manufacturing method.

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1. What is Denim?

Denim is a sturdy fabric made from 100% cotton fiber that typically comes in a shade of blue and is commonly used for making jeans, jackets, and other clothing items. Denim jeans’ durability is derived from weaving together two different-colored yarns, creating a cross-hatched pattern that gives the fabric greater strength than many other cotton types. Denim is well-known for its versatility and can be used to create many different looks, textures, and styles.

denim garment manufacturing process
Denim is a sturdy cotton fabric that is commonly used for making clothing items

2. Denim garment manufacturing process

With unique durable quality and trendy aesthetic value, denim has become one of the most popular fabrics for clothing items such as jeans, jackets, and skirts. However, few people realize that the denim cloth manufacturing process is a complex one that requires careful attention to detail and in-depth knowledge of the fabric and its properties. In this article, Dugarco – a Vietnam clothing manufacturers will take a closer look at the various stages involved in the denim garment manufacturing process.

2.1. Blending the Cotton

Blending is an important part of the denim garment manufacturing process. It helps to ensure consistent quality and uniformity in the final product. The process of blending involves mixing various cotton batches to produce a blend that satisfies certain requirements for strength, texture, and colour.

denim garment manufacturing process
Blending the Cotton process

Typically, impurities like seeds and weeds will be cleaned out of the cotton blend by scraping off each bale and bringing it into a mixer. After being washed, the cotton is blended with other batches of cotton to produce a homogenous mix. Using specialized equipment or by hand are both popular methods of blending.

2.2. Spinning of Cotton

An essential stage in the creation of cotton textiles is spinning. Cotton fibres are twisted and drawn out into a very long, continuous thread. Cotton spinning is a highly specialized procedure that requires skill and expertise to produce the end product with the ideal uniformity and quality.

denim garment manufacturing process
Cotton spinning process

2.3. Thread dyeing or coloring

The bulk of the denim garments is coloured in the recognizable blue-indigo shade. This is one of the earliest dyes still in use today for denim manufacturing. Currently, there are 2 dyeing methods, including indigo dyeing and non-indigo dyes:

  • Indigo dyeing: A critical step in the denim garment manufacturing process is indigo dyeing, which involves dying the warp yarns using either the rope or slasher dyeing methods. Indigo-dyed denim has the unique ability to achieve a wash-down effect after several piles of washing without losing the vibrancy of its colour. However, the dyeing procedure presents several difficulties, including the need for reducing agents and the production of a substantial volume of effluents.
manufacturing clothes process
Thread dyeing or colouring process
  • Non-indigo dyes: As an alternative to conventional indigo dyes, non-indigo dyes, sometimes referred to as sulphur dyes, are being utilized more frequently in the denim warp dyeing process. They have a larger selection of colours and are a better choice for the environment. Using contemporary dyeing procedures, sulphur dyes have a better affinity for cotton fibres, resulting in a more effective dying process and reduced water utilization.

2.4. Denim fabric weaving

Weaving is the last step in denim processing, and it significantly affects the quality of the finished item. Denim fabric is woven as a 3/1 twill using an interlaced warp and grey weft. The weight, fabric tightness, cover, drape, tensile strength, and other properties of the fabric are influenced by the yarn counts. Even though denim weaving is now a highly automated process, high-quality denim fabric still requires skill and accuracy to be produced.

manufacturing clothes process
Denim fabric weaving step

2.5. Techniques for joining – Denim garment manufacturing process

The joining techniques that are used to produce denim jeans and play a significant part in shaping, fitting, and styling the product. The flat-felled seam is a popular technique in which the edges of two pieces of cloth are folded over and sewn together to produce a neat and durable seam. Overall, the joining techniques employed in the denim garment manufacturing process demand accuracy and close attention to detail in order to produce long-lasting, fashionable items.

manufacturing clothes process
Techniques for joining in the denim cloth manufacturing process

2.6. Denim digital printing

Digital printing can be considered one of the most popular techniques for denim colouration. Unlike traditional methods of printing on denim, digital printing uses specialized inkjet printers to apply ink directly onto the fabric and allows for more intricate and custom designs to be printed onto denim fabric.

denim cloth manufacturing process
Denim digital printing in the denim garment manufacturing process

Additionally, because it uses less water, chemicals, and trash than conventional printing techniques, digital printing is more environmentally friendly. Therefore, it is evident that digital printing provides economic and environmentally-friendly alternatives to traditional colouration and washing techniques.

2.7. The washing clean of denim

The denim garment washing technique is an important process that can affect the aesthetic value and durability of the denim fabric. From a stiff and dull blue fabric without any fashion appeal, washing is the revolutionary process that has changed this mundane image of denim, giving them a variety of unique colours.

denim manufacturing
The washing clean of denim

Denim garment washing depends greatly on the use of chemicals and stones for the purposes of accomplishing the effects of colour fading and softening. As a result, they produce an effluent issue, raising concerns about the process’s sustainability. However, with ever-improving technology, dry treatments or nearly water-free treatments are slowly becoming a sustainable trend for replacing traditional wet treatments in denim garment washing.

2.8. Denim garment finishing process

The finishing process is an important phase in the denim cloth manufacturing process, which affects both the aesthetic and practical qualities of denim clothing. There are countless dry and wet processes in denim garment production to achieve fading, excellent handling, and distinctive styles. In addition to these processes for creating unique design effects, several functional finishes can also be applied to denim garments to generate distinctive fashion effects.

denim manufacturing
Denim garment finishing process

2.9. Inspection

The final stage in the denim garment manufacturing process is inspection because any possible weaving fault may be detected. After a specified period of time, the rolls will be got and checked by an inspection machine. Then, it goes through various finishing inspection processes such as brushing, singeing, washing, impregnation and thus producing the final denim garment product.

denim manufacturing
Inspection step in the denim jeans manufacturing process

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3. Various denim product types

There are now numerous types of denim products available on the market, each with its own unique style and features. Here is the list of denim product types.

  • Denim shirt, long T-shirt
  • Denim pants, jeans, trousers, short jeans pant
denim manufacturing
Denim shirt is a denim product type
  • Denim jacket, denim sleeveless jacket
  • Denim skirt, denim piper skirt, denim crossover skirt
  • Denim shoes
  • Denim bags
  • Denim caps

The following article has provided you with more information about the denim garment manufacturing process. Please don’t hesitate to contact Dugarco for detailed advice if you have any queries or would want to know more about this production process.

Contact information:

  • Address: 59 Đức Giang, Đức Giang, Long Biên, HN
  • Phone: 024 3655 7930
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