Denim Production

8 processes involve in making denim fabrics
(Ref & Pictures are from Pepe Jeans)

1. Opening and Blending- arrival and opening of bulk raw cotton from farms. Those bulks of raw cotton are as hard as bolder. So the process of Opening the cotton is loosening it and separating it into tufts. Since different varieties of cottons were delivered, on this stage, they blended it to make a consistent fabric.

2. Carding- cotton are back to its original state, web of fibers, cotton you usually see fell from the trees; which they called lap. Stick, seeds, leaves and other impurities are removed by passing thru the cottons on the teeth like structure of metal sticks. This process is what we call carding. After carding, cotton laps are now in parallel to each other inserted into trumpet tube to create sliver. Slivers are cotton lose rope.

3. spinning- As for pre-preparations for spinning, six slivers are combined together to form a stronger one sliver. Further twisted to create thinner yarn known as roving. More drawing and twisting are done by spinning machine to create ring spun. Ring spun used for warp is more tightly twisted than for weft ring spun.

4. Warp & Weft Yarn- lengthwise yarn of the fabric is what we call WARP. Crosswise yarn of the fabric is what we call WEFT. Weft yarn are as known as filler since it acts as filler for warp yarn in weaving. Since it is only fillers, shorter fibers are used to make weft ring spun.

5. Dyeing- before passing thru the large cylinders of dyeing machine, yarn are combine together to make a rope---->>wash of sulfur and indigo---->>drying cans---->> coiled into lose ropes in a tube container.

6. Beaming- after separating the rope back into yarn, it is now ready for starching to make it smooth and stiff which supports the yarn for abrasion and tension during weaving.

7. Weaving- after spreading the warp yarn on the loom and weft yarn fed in to the loom, machine will start weaving by crossing natural undyed weft yarns between warp yarns.

8. Finishing- to clean astray yarns, flame is brushed and signed into the fabric. and then following are done to finish denim fabric:
stretched to its proper width
skewed to prevent twisting
moistened and compressed bet iron plates to prevent shrinkage
rolled ready for manufacturers' purchases