Denim Jeans Manufacturer and Supplier

Types of Denim Fabric used in Manufacturing of Jeans

Denim is a sturdy cotton fabric that is typically used in the manufacturing of jeans. Denim textiles come in a variety of forms, each having special properties and applications. Some of the most well-liked denim fabric types used to produce jeans are listed in the list below:

1. Raw Denim: The term “dry denim” or “raw denim” refers to denim that has not been washed or otherwise processed. This type of denim is stiff and rigid initially, but it softens with time and takes on the wearer’s unique shape.
2. Selvedge Denim: Selvedge denim is a type of denim fabric that is woven on traditional shuttle looms. It has a clean, self-finished edge that prevents fraying and unravelling. Due to its higher quality and labor-intensive manufacturing method, selvedge denim is often more expensive than other denim kinds.
3. Stretch Denim: A form of denim fabric with elastane or spandex fibres that give it an elastic characteristic is known as stretch denim. Form-fitting jeans are best made from this sort of denim since it is softer and more forgiving than stiff denim.
4. Acid Wash Denim: Acid wash denim is a type of denim fabric that has been treated with chemicals to create a faded or worn look. A resurgence of this style of denim in contemporary style has occurred since the 1980s.
5. Lightweight Denim: Compared to other denim fabrics, lightweight denim is thinner and more breathable. For individuals who want a looser, more comfortable fit or for warmer weather, this kind of denim is perfect.
6. Coloured Denim: Coloured denim is a type of denim fabric that comes in a range of colours beyond traditional blue. This type of denim is a great way to add colour to your collection and can be dressed up or down depending on the situation.
7. Heavyweight Denim: Compared to other forms of denim, heavyweight denim is a sort of denim fabric that is thicker and more robust. This type of denim is commonly used in workwear and for jeans that are designed to withstand heavy use and abuse.
8. Coated Denim: Coated denim is a kind of denim fabric that has undergone a coating or film treatment to give it a lustrous or leather-like look. This type of denim is popular for creating a sleek, modern look.
9. Printed Denim: Printed denim is a type of denim fabric that has been printed with patterns or designs. This type of denim is a fun way to add visual interest and personality to your jeans.
10. Bull Denim: Bull denim is a type of denim fabric that is woven with a diagonal twill pattern. This type of denim is best for workplace/workwear and outdoor clothing since it is often thicker and more robust than other varieties of denim.
11. Organic Denim: “Organic denim” is a type of denim fabric made from cotton that has been grown without the use of harmful fertilisers or pesticides. Being sustainable and ecologically beneficial, this kind of denim is a great option for individuals who care about the environment.

The above are just a few more illustrations of the various denim fabric kinds that may be used to make jeans. One’s personal preferences, the sort of jeans you want to make, and how you want to use them will all influence the type of denim you select.

Types of Weaving used for making of Denim Jeans

Denim weave or “twill weave” is the term for the weaving method used to create denim jeans. This kind of weaving produces the distinctive diagonal ridges or lines on the fabric’s surface by weaving the cloth in a diagonal pattern.

There are two types of denim weaves commonly used in making jeans:

• 2×1 twill weaves
  • In a 2×1 twill weave, the fabric is woven with two warp threads crossing over one weft thread.
• 3×1 twill weaves
  • In a 3×1 twill weave, the fabric is woven with three warp threads crossing over one weft thread.

The difference between these two weaves is the angle and direction of the diagonal pattern on the fabric.

The twill weave is ideal for making denim fabric because it creates a durable and strong fabric that can withstand heavy use and wear. The diagonal pattern on the fabric also adds visual interest and texture to the finished product.

In addition to the twill weave, other weaving techniques may also be used in making denim jeans, such as:

1. Satin Weave: A satin weave produces a smooth and shiny fabric that has a lot of drape and is ideal for dressier jeans.
2. Herringbone Weave: A herringbone weave produces a distinctive “V” shaped pattern on the fabric and is often used for denim jackets or other outerwear.
3. Basket Weave: A basket weave produces a textured and breathable fabric that is ideal for lightweight denim.

Ultimately, the weaving technique used in making denim jeans depends on the intended style and use of the jeans, as well as the preferences of the designer and manufacturer.

What are the different types of denim washes?

These are the most common types of washes used in manufacturing denim jeans. The type of wash used will depend on the desired look and style of the jeans, as well as the preferences of the designer and manufacturer.

1. Stone Wash: Stone wash is the most common type of wash used in denim jeans manufacturing. It involves washing the denim with pumice stones to create a faded, distressed look.
2. Acid Wash: Acid wash is a type of wash that uses chemicals to create a worn, vintage look. It involves soaking the denim in a solution of chlorine and pumice stones to create a faded, bleached effect.
3. Rinse Wash: Rinse wash is a type of wash that involves washing the denim in water to remove any excess dye and soften the fabric. This creates a clean, dark finish.
4. Enzyme Wash: Enzyme wash is a type of wash that uses enzymes to break down the fibers of the denim and create a faded, worn look. This type of wash is commonly used to create a vintage, lived-in look.
5. Bleach Wash: Bleach wash is a type of wash that involves bleaching the denim to create a lighter, more faded look. Several other washing methods, such as spray bleach, dip bleach, and acid wash, can be used for this sort of wash.
6. Vintage Wash: A style of wash meant to resemble the appearance and texture of old denim. To get a distinctive, worn-in effect, this style of wash combines many wash procedures, including bleach wash and stone wash.
7. Overdyed Wash: An overdyed wash is a form of wash in which the denim is dyed after it has been cleaned and processed. This creates a deep, saturated colour that is often used in high-end denim jeans.
8. Dirty Wash: Dirty wash is a type of wash that creates a “dirty” or “gritty” look on the denim fabric. It involves treating the denim with various chemicals and abrasives to create a worn-out appearance.
9. Tinted Wash: Tinted wash is a type of wash that involves adding a tint or hue to the denim fabric. This type of wash is used to create a unique, coloured look on the denim.
10. Whisker Wash: Whisker wash is a type of wash that creates whisker-like creases on the front of the denim, typically around the thigh area. This is done by using sandpaper or a laser to create a worn-in look.
11. Resin Wash: Resin wash is a type of wash that involves coating the denim with a resin-like substance to create a stiff, polished look. This type of wash is often used to create high-end, designer jeans.
12. Raw Denim: Denim that has not been cleaned or treated in any manner is known as “raw” denim. This kind of stiff, usually dark denim is designed to be worn and washed repeatedly to develop a distinctive, individual appearance.

Different Weightages in Denim Jeans

Denim can be categorized by its weight, which is typically measured in ounces per square yard (oz/yd² or oz/lyd). Here are some common weight categories and their usage in the international market and regions:

1. Lightweight Denim (under 10 oz/yd²): Lightweight denim is typically used for warm weather clothing, such as shorts, skirts, and lightweight jeans. Southeast Asia and South America are two places with hot, humid temperatures where this kind of denim is common.
2. Mid-Weight Denim (10-14 oz/yd²): Denim that is mid-weight (10–14 oz/yd2) The most popular weight category for denim is mid-weight, which is utilised for a range of garments like jeans, jackets, and skirts. In areas with temperate temperatures like North America, Europe, and Australia, this kind of denim is common.
3. Heavyweight Denim (over 14 oz/yd²): Heavyweight denim is typically used for durable workwear, such as overalls and jackets. This type of denim is popular in regions with cold climates, such as Northern Europe and Canada.
4. Super Lightweight Denim (under 6 oz/yd²): Super lightweight denim is a newer category that has gained popularity in recent years. It is frequently utilised for shirts and dresses as well as other lightweight, breathable garments. Southeast Asia and other hot, humid regions are known for their love of this style of denim.

Denim Jeans Styles

Denim jeans come in a wide variety of styles, each having a distinctive fit, cut, and appearance. Listed here are a few of the most popular denim jean designs:

• Straight Leg: A traditional shape that flatters a variety of body types, straight leg jeans feature a constant width from the hip to the ankle.
• Skinny: Skinny jeans are tight-fitting and tapered at the ankle, with a narrow leg opening. They are a popular style for both men and women and are often made with stretch denim for added comfort.
• Bootcut: Bootcut jeans have a slight flare at the bottom of the leg, which is designed to accommodate boots or other footwear. They are a versatile style that can be dressed up or down.
• Flared: Flared jeans have a wider flare at the bottom of the leg than bootcut jeans, and were popular in the 1970s. They are making a comeback in recent years as part of the retro fashion trend.
• Wide Leg: Wide leg jeans have a wider cut throughout the leg, creating a relaxed and comfortable fit. They can be dressed up or down and are a popular style for both men and women.
• Boyfriend: Boyfriend jeans have a loose, relaxed fit and are designed to look like a woman is wearing her boyfriend’s jeans. They are typically worn cuffed at the ankle and can be dressed up or down.
• Mom Jeans: Mom jeans are a high-waisted style with a loose, relaxed fit through the hips and thighs. They are often tapered at the ankle and are popular as part of the retro fashion trend.
• High-Waisted: High-waisted jeans have a waistline that sits above the natural waist, creating a slimming and elongating effect. Several designs are offered, including slim, straight leg, and wide leg.
• Low-rise: Low-rise jeans have a waistline that sits below the natural waist, often on the hips. They come in a variety of designs and shapes, from thin to bootcut, but their appeal has declined since the early 2000s.
• Tapered: Tapered jeans have a wider leg at the top and gradually taper down to a narrower leg opening at the ankle. They can be found in various styles, from a loose fit to a more slim fit.
• Cropped: Cropped jeans are cut to end above the ankle, creating a cropped or capri-length style. They can be found in various cuts and styles, from straight leg to skinny, and are popular in warmer weather.
• Jegging: Jegging is a combination of jeans and leggings, created by using stretch denim fabric to make a legging-like style with the appearance of denim jeans. They are form-fitting and often have an elastic waistband.
• Distressed: Distressed jeans are intentionally designed to look worn or distressed, often with ripped or frayed areas. They can be found in various styles and cuts, from skinny to boyfriend, and are popular in both casual and fashion-forward settings.
• Cargo: Cargo jeans have additional pockets and cargo-like features, giving them a more utilitarian appearance. They can be found in various styles and cuts, from skinny to wide-leg, and are popular in workwear and military-inspired fashion trends.

Common Types of Jeans

There are several sorts of jeans, each with a distinctive set of characteristics, fashion, and uses. Here are some of the most common types of jeans:

• Classic blue jeans: This is the quintessential style of denim jeans, typically made from blue denim fabric and featuring a five-pocket design, zipper fly, and button closure. They are a versatile style that can be dressed up or down.
• Black jeans: Black jeans are a common substitute for traditional blue jeans and are frequently worn as part of a dressier or more formal ensemble. They come in many different cuts and designs.
• Colored jeans: Colored jeans come in a variety of tones, from vivid and eye-catching to more subdued. They are a fun and playful option that can add a pop of color to any outfit.
• Acid wash jeans: Acid wash jeans have a distinct washed-out appearance, created by using acid to bleach and distress the denim fabric. They were popular in the 1980s and have recently made a comeback as part of the retro fashion trend.
• Ripped jeans: Ripped jeans have intentional tears or frayed areas, giving them a more distressed and worn look. From narrow to wide-leg, they come in a range of shapes and styles.
• Embroidered jeans: Denim fabric is embellished with elaborate embroidery patterns to give embroidered jeans their unique feel and level of detail.
• High-waisted jeans: High-waisted jeans feature a waistband that rests above the natural waist, giving the appearance of a slimmer, longer figure. They come in many different styles, such as slim, straight leg, and wide leg.

Certifications Recommended for Bulk Denim Jeans Production and Import

There are several certifications that are important to consider when manufacturing bulk denim jeans, depending on the country of manufacture and the target market. Here are some of the most common certifications:

1. Oeko-Tex Standard 100: This is a certification for textile products that ensures they are free from harmful substances and safe for human use. The entire production process is covered, from the initial raw materials to the completed result.
2. Global Organic Textile Standard (GOTS): This accreditation guarantees that the organic fibres used to make denim were cultivated without the use of artificial fertilisers and pesticides. It also requires that the entire supply chain meets strict environmental and social standards.
3. Better Cotton Initiative (BCI): This is a certification that ensures the cotton used in the production of the denim is grown sustainably, with a focus on reducing water usage and pesticide application.
4. WRAP: Worldwide Responsible Accredited Production (WRAP) certification ensures that the production process meets high ethical and social standards. It includes requirements for fair labor practices, workplace safety, and environmental sustainability.
5. ISO 9001: This is a quality management certification that ensures the denim manufacturer has a system in place to consistently provide high-quality products and meet customer requirements.

Customers may be assured by these certificates that the denim jeans they are buying have been produced in an ethical and sustainable manner with an emphasis on quality and safety.

Embellishments used in making of a denim jeans

A denim pair of jeans can be adorned with a wide variety of decorations, such as:

• Rivets: Rivets are metal fasteners that are positioned at stress locations, such as the corners of pockets, to strengthen the fabric and stop it from ripping.
• Buttons: Buttons are used to fasten the waistband and the fly of the jeans. They can be made from metal, plastic, or other materials.
• Zippers: Zippers are another option for fastening the fly of the jeans. They are typically made from metal or plastic.
• Embroidery: Embroidery is a decorative stitching method that may be used to accentuate the denim fabric with motifs or patterns. It is often used to create logos, graphics, or other designs on the back pockets of the jeans.
• Patches: To provide a decorative touch, patches are fabric pieces that are sewed into denim. They can be used to conceal holes or other fabric damage and are constructed of denim or other fabrics.
• Studs: For a decorative impact, little metal decorations called studs can be applied to the pockets, waistline, or other parts of jeans.
• Rhinestones: Rhinestones are small, shiny stones that can be added to the denim fabric for a sparkly effect.
• Paint: Paint can be used to add designs or patterns to the denim fabric. It is often used to create a distressed or vintage effect.
• Appliques: Appliques are decorative pieces of fabric that are sewn onto the denim fabric. They can be used to add patterns or designs to the jeans, or to cover up holes or other damage to the fabric.
•  Fringe: Fringe is a decorative trim made from strips of fabric that are left uncut at the ends. It can be added to the hemline or other areas of the jeans for a bohemian or western-inspired look.
• Distressing: Distressing is a technique used to give the denim fabric a worn or faded look. This can be done using sandpaper, bleach, or other methods to create holes, frayed edges, or other types of damage to the fabric.
• Applique patches: Applique patches are fabric pieces that are cut into specific shapes or designs and then sewn onto the denim fabric. They can be used to add a pop of color or to create a specific design or pattern.
• Lace: Lace is a delicate fabric that can be added to the denim fabric for a feminine touch. It is often used to create a bohemian or vintage-inspired look.
• Leather patches: Leather patches are often used on the back waistband of denim jeans to display the brand logo. They can also be used in other areas of the jeans for a decorative effect.
• Prints: Prints can be added to the denim fabric using a variety of techniques, such as screen printing or digital printing. They can be used to create patterns, designs, or logos on the fabric.

AQL Standards

AQL (Acceptable Quality Level) standards are used in the garment industry to ensure that the final product meets a certain level of quality. The following are the AQL standards required for denim jeans, categorized by their subcategories:

• Critical Defects:
  • Dimensional measurements: 1.0
  • Skewing: 1.5
  • Misaligned pockets: 2.5
  • Leg twistedness: 1.5
• Major Defects:
  • Broken stitches: 2.5
  • Open seams: 2.5
  • Stitch skip: 2.5
  • Raw edges: 2.5
  • Fabric hole: 2.5
• Minor Defects:
  • Loose threads: 4.0
  • Press mark: 4.0
  • Oil stain: 4.0
  • Dirt stain: 4.0
  • Incomplete buttonhole: 4.0

The AQL standards for denim jeans can vary depending on the specific requirements of the customer or brand. However, the above standards are considered as the general guidelines for acceptable quality levels in the denim industry.

Frequently Asked Questions (FAQs) – Denim Jeans Manufacturing & Sourcing