How jeans are made?

Introduction:
Jeans; for past recent years its a vulgar wearing textile in this universe & we cant even create a
controversy about the domination of this textile. Before preaching we need to be start with the
technical meaning of jeans. So the term Jeans technically means that The garments that mad
of denim can be termed as jeans. There is no doubt that hoe popular it is, everybody including
men, women, kids looks so good with a jeans. And comparatively it is cheap then other textiles
for wearing. Its also popular for its strength & lifetime. In every year 450 million pairs of jeans
sold in USA and worldwide income 40 billion dollars.
The story of jeans begins in the city of Genoa, in Italy, famous for its cotton corduroy, called
either jean or jeane.

Fig: Jeans.
Flow Chart of Jeans production:
Cotton
Harvesti
ng

Cotton
Blendin
g

Cotton
Ginning

Doublin
g&
Drafting

Carding

Beamin
g

Spinning

Weaving

Yarn
Dyeing

Finishing

Garments
Making

Cotton harvesting:
In Mexico the story of cotton harvesting commences about 650 km away and on the plains of
Thoreau. For the past many years, a labor could collect at best 50 kg of cotton fiber per day. But
now, they use mechanical system it can collect about 50kg cotton within 5 minutes. Actually the
function of this machine is to pick the cotton fiber between the rotating cylinder and this separate
the cotton from this stands. A suction system let the fibers to enter to the basket. After
accomplishing this task the basket is compressed in a high pressure to make easy to carry. In this
moment the cotton fiber contains a huge amount of seeds & leaves respectively 500kg & 100kg
where the cotton fiber amount is only 400kg in a bail of 1000kg.
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Cotton Ginning:
It is necessary to separate the cotton fibers from the seeds, leaves and other impurities to get a
quality full product. Hence ginning is done, it looks like a giant machine where the cotton fibers
are thrown and this machine performs basically drying & cleaning. After cleaning the cotton
fibers that are pure and lengthy fibers are formed into a package known as bail where the weight
of that package may be 200kg and interesting thing is from this package we can make
approximately 325 pairs of jeans.
Cotton blending in blow room:
Since the cotton is collected from different types of plants or places of that other those plants of
different maturity, length, strength and other important issues to providing a good quality yarn,
the fibers from different bails need to be mixed, in another word needs to blend. This machine is
called Trutzschler blended matt.

Fig: Process of blending.

Fig: Carding.
Doubling & Drafting: In order to achieve desired yarn characteristics this process must involve
with proper drafting arrangement. This process is done in a draw frame where the draft amount is
kept 6. The speed of the feed of kept 1500 feet/min.
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Spinning:
The spinning that shown in this video is rotor spinning where there is no roving & simplex like
ring spinning. Improve evenness through back-doubling. To impart strength by twisting. Here
the slivers are given more draft extension where the ring speed remains 120000 revolutions per
minute. Actually there are about 100 to 250 fibers in a certain cross section of yarn & such this
type of yarn of 1 km made from 20gm of fibers sample.
Beaming & Dyeing:
After beaming the cotton yarn needs to be dyed. In this case the yarn is dyed with indigo dyes as
we know that the indigo dye is not water soluble, so to make is water soluble it needs to reduce
with a proper reducing agent is called sodium hydro shulphide or sodium dithionite or any other
reducing agent. This is why the preliminary color of the solution is yellow. After the reducing
agent is removed by oxidation, the color converted into blue. The yarns are treated with some
cold starch to make it stiffer and then they are subjected to dry.

Fig: Beaming.

Fig: Dyeing.

Weaving:
The next step is weaving where two sets of yarns are interlaced. Hence the blue colored yarn are
used as warp & the white colored yarn are used as weft. The ratio of blue & white colored yarn is
respectively 3 & 1. This type of weaving is done in an air jet loom & it is a fast loom & thus
every week this Denimer of Mexico can produce approximately 3000m denim then the next
process is jeans making.
Garments manufacturing:
The prepared goes to the largest factory of jeans making in Mexico. This factory the first choice
of Americans and this factory can produce 400000 pairs every month. The flow chart of the
garments making is given below.
Pattern and marker making:
The task of pattern making is performed by a computerized system where the model is stored
before. At first, designed in a hard paper called pattern paper. The marker is done by computer
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with some specific designing software generally termed as CAD (computer aided design) by an
experienced operator.
Fabric Spreading:
Spreading means to spread the roll on the cutting table. The fabric is spreaded semi mechanically
where the main aim is to spread the fabrics one over one with caring the uniformity & avoiding
the folding.
Cutting:
After maker making the task of cutting begins. It means to cut the fabric form the lay according
to the design of the maker. The main task of cutting that is bigger parts is cut with the straight
knife cutting machine.
Sewing:
It is the most desired part of garment making. Here the parts those comes from cutting are sewn
precisely. About 15 minute requires producing a pair of jeans. In case of accessories it needs
about seven hundred meters of thread, 6 rivets & one zipper or 5 buttons.
Finishing:
After making jeans, the main task of the garments it to improve its look. It is the time to concern
about the product quality; this is why the raw garments are treated with some mechanical and
chemical procedure. The process flowchart of finishing in garments is given below.
The garments are sent to the ironing section and the garments ironed manually, a worker can iron
300 pair of jeans per day. The jeans are grinded at some specific parts and it is done with a rough
rotating device. The sprayed jeans are treated with leaser to gain specific color. Jeans are pressed
labeled thus making ready to pack. Jeans are shooting to see when the color fades away. Here the
pairs are faded out by rough brushing. It is easy to brush out color as the bond between fabric &
color is not so good. Stains are sprayed on the fabric to get proper action to leaser. The jeans are
then washed with volcanic rock to reduce the stiffness. Finally the jeans are packed together &
sent to store or buyer.
Conclusion:
From this assignment, we leant about whole process of jeans production. We also gain vast
knowledge about cotton harvesting, spinning, weaving, dyeing & finishing of jeans. So, it is very
important. This assignment also will help us in our future life.

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