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Denim is a strong durable fabric constructed in a twill
weave with indigo and white yarns. The story of jeans
begins in the mid-19th century simultaneously in two
European cities: Nîmes in France, where the fabric itself
was created, the so-called “Serge de Nîmes” which led
to the name “denim”. Genoa in Italy, where the color
comes from, called in French “Bleu de Gênes” which led
to the expression “blue jeans” .The fabric and color come
together to become the jeans, denim.
5. Cotton grows in a vast field. Picking cotton by hand is a slow
back breaking work. Each picker can only pick around 50kg a
day. But the mechanical cotton picker, its takes only five
minute to pick cotton that a man can pick in whole day. Then
cotton comprised in a massive bale which is ready for
transportation. Each ton of bale contain 500kg seeds, 100kg
leafs and only 400kg of cotton fiber.
6. Cleaning was always an important
basic operation and it will become
steadily more important. For one
thing, due to machine harvesting
cotton contains more and more
impurities, which furthermore are
shattered by hard ginning. The
higher the degree of opening, the
higher the degree of cleaning. A very
high cleaning effect is almost always
purchased at the cost of a high fiber
loss.
7. Intensive blending in a suitable blending machine must be
carried out after separate tuft extraction from individual bales of
the layout. This blending operation must collect the brunches
of fibers arriving sequentially from individual bales and mix
them thoroughly. Multi mixer is the machine of blow room
where the uniform blending is carried out.
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Carding is the reduction of
entangled mass of fibers to filmy
web by working them between two
closely spaced relatively moving
surfaces closed with sharp points.
It is done to remove any foreign
matter and the short fibers so that
cotton takes the form of a web
which is then converted into a
rope like form called sliver..
9. The drawing process produces a single, uniform Sliver from a number
of carded slivers. It is straighten the crimped and hooked fibers in the
card sliver. It also achieve a fairly through parallelization of the fibers
along the sliver axis, so that when they came to be spun on the spinning
frame they will be evenly drafted and twisted to produce an acceptable
yarn.
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Spinning is a major part of the textile industry.
Ring-spinning is the most common spinning
method in the world. Other systems include
air-jet and rotor or open-end spinning. Rotor
spinning is done using break or open-end
spinning. This is a technique where the staple
fiber is blown by air into a rotor and attaches
to the tail of formed yarn that is continually
being drawn out of the chamber.
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The parallel winding of warp ends from many winding packages on
to a common package (warp beam) is called warping. To arrange a
convenient number of warp yarns of related length so that they can
be collect on a single warp beam as a continuous sheet of yarns
which can be used for sizing or next process.
12. There are various dying and sizing processes of yarns, which can be
classified into four categories. Continuous Indigo-rope dying and
sizing , Continuous dying and sizing, Indigo-back beam dyeing and
sizing and Continuous dyeing and sizing. In indigo-back beam, dyeing
and sizing is done in two stages. In the first stage, back beams are dyed
, oxidized , dried and wound on a batch roll. The batch roll is then
sized, dried and wound on a weavers beam.
13. The most usual weaving structure used in denim fabric is Twill. Twill
weave is normally designated as a fraction, such as 3/1. In this case the
numerator indicates the number of harnesses which are raised when
the filling thread is inserted (in this case it is 3). The denominator
indicates the number of harnesses that are lowered when the filling
thread is inserted (in this case is 1). Weaving is done by Air jet, Water
jet, Rapier or a Projectile weaving machine..
14. Produced fabric is come into the garments factory for further
processing. Firstly Marker is making efficiently, then Spreading the
fabric using spreading machine and finally Cutting the fabric using
cutting machine. Each pair jeans takes 15 min to make, including 1.6
meter denim, 1 zipper , 5 button etc. This jeans still not ready to use. It
is then Blown up and stretched for 60 min.
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In order to accelerate the garment wash effect and to give
garments an even more unique appearance and softer
hand, abrasive stones were introduced to the wash bath.
17. Finally the fabric is ready for use and it packed and send to the consumer.
