What is Denim?
Denim is a strong cotton warp face textile where the weft runs under two or more warps. This dual weave creates a diagonal ribbon that separates it from the cotton duck. Although a denim predecessor was known as Dungaree was produced in India for hundreds of years, denim itself was first produced in the French city of Nîmes under the name Serge de Nimes.
The most common denim is blue denim, in which the warp thread is dyed, and the weft
thread is white. As a result of the double weaving of the left warp face, the
textile texture is dominated by blue warp thread on one side and white weft
thread on the other. It turns white inside the blue jeans. The blue dyeing
process, where the core of the warp threads is white, creates the signature
fading properties of denim.
Historical background of Denim
The
name "denim" derives from the French sergé de Nîmes, meaning 'serge
from Nîmes'.
The tradition for making denim blue jeans was traditionally blue, although jeans previously meant a different lighter, cotton fabric. The contemporary use of the word "jeans" comes from the French word for Genoa, Italy: Gênes.
Today's fashion is incomplete without denim. It has been used in the United States since the mid-19th century. Denim first gained popularity in 1873 when Jacob W. Davis, a tailor from Nevada, manufactured the first pair of rivet-reinforced denim pants. At this time, clothes for Western laborers, such as teamsters, surveyors, and miners, were not very durable. Her idea of making strong jeans was inspired when a customer requested a pair of durable and sturdy pants to cut wood for her husband. When Davis was about to finish making the denim jeans, the popularity of denim jeans began to spread rapidly. Davis was overwhelmed with requests and sold 200 pairs to workers in need of heavy work clothing. Throughout the 20th century, denim was used for cheap durable uniforms like those issued to the staff of the French national railways.
Denim processing from fiber to finish garments
Producing of denim
All
denim is produced through generally the same process.
a. At first, cotton is harvested by hand or machine.
b. A cotton gin separates the cotton fiber from
the seeds.
c. The cotton fiber is spun into yarn.
d. The yarn is dyed.
e. The dyed yarn is woven on a shuttle loom or
projectile loom.
f. The woven product is Sanforized.
Denim yarn production
Most denim, yarn is made from cotton fiber. At present different type of
blended yarn is also used. Blended yarn is used for comfortable. Some denim
yarn may use an elastic component such as spandex for up to 3% of the content
to allow the final woven product to stretch. Even such a small amount of
spandex enables a stretching capacity of about 15%.
Denim fabric dyeing
Denim
was originally dyed with indigo dye extracted from plants, often from the
Indigofera family. In South Asia, indigo dye was extracted from the dried and
fermented leaves of Indigofera tinctoria; this is the plant that is now known
as "true indigo" or "natural indigo". In Europe, the use of
Isatis tinctoria, or woad, can be traced back to the 8th century BC, although
it was eventually replaced by Indigofera tinctoria as the superior dye product.
However, most denim today is dyed with synthetic indigo dye. In all cases, the
yarn undergoes a repeated sequence of dipping and oxidation — the more dips,
the stronger the color of the indigo.
Denim fabric dyeing is divided into two categories: indigo dyeing and sulfur dyeing.
Indigo dyeing produces the traditional blue color or shades similar to it.
Sulfur dyeing produces especially black colors and other colors, such as red,
pink, purple, grey, rust, mustard, and green.
Denim fabric manufacturing
Today,
most of the denim is made on a shuttleless loom that produces bolts of fabric
60 inches or wider, but some denim is still woven on the traditional shuttle
loom, which typically produces a bolt 30 inches wide. Shuttle-loom-woven denim
is typically recognized by its selvage, the edge of a fabric created as a
continuous cross-yarn (the weft) reverses direction at the edge side of the
shuttle loom. The selvage is traditionally emphasized with warp threads of one
or more contrasting colors, which can serve as an identifying mark.
Although
quality denim can be made on either loom, selvage denim has come to be
associated with premium products since the final product that showcases the
selvage requires greater care for assemblage. The thickness of denim can vary
greatly, with a yard of fabric weighing anywhere from 9 to 24 Oz, with 11 to 14
Oz being typical.
Denim Garments Manufacturing
At
first denim fabric checking with a 4-point system. After 100% check, the fabric
lay down on the cutting table. Then marker making and placing on the laydown
fabric. Draw patterns for each portion of the garments. Then cut and numbering
every potion for avoiding mistakes. After that need proper sewing of each portion another. Then check all the garments and send them to washing for the
perfect wash.
Denim Garments Washing
Without
wash, denim garments are rigid and have raw looks. So wash needs color fading, a worn-out look, and softness. Different types of wash are done for a good outlook.
Such as rinse wash, enzyme wash, enzyme-bleach wash, different types of acid
wash, softener wash, and so on. After washing denim garments as soft and attractive
as we want. Different type of dry processes is done on denim garments. Such
are- whiskers, hand sand, tacking, tie, and so on.
Denim Garments Finishing
After
different finishing processes, denim garments look gorgeous and much more
attractive, than raw garments. Different types are finishing, such as adding a
leather patch, rivets, buttons, ironing, and so on.
Conclusion
Today's fashion is incomplete without denim. Denim has versatile use all over the world. So it has a lot of opportunities for our national income.
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