We all have them. We all love them. They come in different sizes, and different colors, adding a style factor in our daily life. Jeans is a staple cloth in everyone’s wardrobe.
But have you ever wondered how they are made? What is their manufacturing process? Or have you ever wondered who invented these masterpieces in the first place? Or why do we call them Jeans?
We have seen a whole evolution in denim industry, which started with straight, loose jeans in 1800, which has now become a fashion must have, for everyone from a celebrity to your local newsboy.
Today we have so many Jeans brands around the world, which can range from thousand bucks to more expensive price.Brands like Buffalo Jeansare nominal priced compared to Levis or Gucci, which can literally cost you a month’s dime.Buffalo jeans price is really affordable for a common man’s pocket.
Brief History About Jeans
The denim cloth also holds an unusual history, which was originated in France. Originally, it was a thick material made up of wool. By the early 1700s, they started mixing cotton in it, which eventually dominated the fabric. Gradually, Genovese sailor started using this material, to create pants, and started calling them ‘Genes’, which was later changed to ‘Jeans’.
Earlier jean zippers were held by buttons, which were replaced in 1920’s. Levis marked the turning point in the popularity of Jeans in 1850, as they started experimenting and changing the fabric and its designs. And slowly year after year more brands took interest in this outfit and evolved this piece of clothing completely.
Today we have over 50 styles of jeans for both men and women. Today we are also able to get the design and size we want without any hassle.
Unlike other pieces of cloth, Jeans are woven and dyed at a single location.Most brands prefer making changes at a single location. Usually, all the buttons, zippers and other studs of your denim are collected from a different company which is later collated and attached to the jeans.
Preparing The Cotton Yarn
First, the cotton yarn and other fabrics is ginned and processed. In this process the cotton is inserted in a machine in which it is cleansed, straightened and gathered into proper threads. Now these threads are stretched and allocated together in proper pattern for second process.
Dying the Yarn
Now that the yarn of the fabric is ready, it’stime to color it into your desired shade. These dyes also explain why your denim fades after multiple washes. Now the dyed yarn is slashed, in order to make these threads stiffer and stronger.
Weaving the Yarn
The next step is to create a cloth from these threads by sewing and spinning them together.These cotton yarns or threads are now weaved together to create a fabric using mechanical looms. These yarns are also combined with other softer threads to add stretch and flexibility into the fabric. Now the Fabric is ready to be cut and transformed into Jeans.
Now that the Fabric is ready, checked and selected, this is then cut and stitched in different sizes. In case the manufacturer wants to add patterns or designs on the fabric, a cardboard is used to print them on the fabric.
This Fabric is put into high speed machines, which cuts 100 layers of this thick fabric within seconds. Now that the fabric is cut, it is processed and put into another machine where it is sewed and stitched.Now pockets and other external fabric are attached with the Jeans to give it a final look.
When work relating to the fabric is done, the manufacturer adds all the buttons designs and zipper on these denims. Now that the Jean is ready, it is checked for any defaults, and the passed items are further sent to the market.
Most brands take this step pretty seriously as it can damage their goodwill in the market. Some brands ensure to check each and every piece of Jean before sending it to the stores. The finished denim is meticulously inspected for any defects. These defects are rated as per the government defined quality scale. Usually government allows the manufacturer to sell even the high rating products.
Waste Fabric and By Products
Now that the manufacturer has made the product, all the remaining chemical, yarn and fabric is put into recycle bin. Most companies ensure to put the biodegradable products into recycling.
Other Byproducts of denim are included into organic pollutants, which can be treated using biological methods. These dumps are not thrown into lakes and streams as it can degrade the quality of the environment. These companies also have to follow the rules provided by government to handle their waste in a proper legal manner as listed by the government.
So here are the answers to all your Jean related question. It’s fascinating to know that just like any other industrial revolution; fashion industry also had its own revolution. In case you are still not satisfied and want to know more about denim manufacturing and the machines involved in the process. Then we recommend you to visit a YouTube video or a search on Google. It is really fascinating that we all wear these tight trousers everyday but didn’t know the story behind their existence. Hope you were able to learn something from this video, and don’t forget to give us a feedback.