Blue Jeans are a staple in the clothing world all because of their strength, quality, and comfort. Blue jeans are created from denim and proven to be an extremely durable article of clothing. This type of clothing has been worn by everyone from sailors out at sea to miners deep inside the earth digging for treasures. Blue Jeans are the sturdiest pair of pants you’ll ever own and they are still considered a fashion trend. We all know exactly what jeans are but I guarantee we have no idea how they are actually manufactured.
This process begins with denim. Denim has been used for hundreds of years and although some components have changed it is essentially the same product. Denim started off by being made solely from wool. It then moved to being created from a combination of cotton and wool. However the blue jeans of today are created and manufactured by using cotton alone. The cotton is what gives denim its extreme comfort. Another important part of blue jeans is their blue color. Dying the material has been done since their creation. This blue color was once produced by creating a dye from the indigo plant however with changes in technology they now have created and solely use a synthetic indigo dye.
In order to make blue jeans you have to begin with two steps: carding and spinning. With the process of carding the cotton is put inside of a machine that contains bent wire brushes. These bent wire brushes will clean, detangle, straighten, ad gather all of the cotton threads into tiny slivers. When these slivers are combined together they are moved to a spinning machine that will turn stretch out then twist the cotton slivers, forming a spool of yarn. After all the cotton slivers have been spun into a yarn they are ready to be moved to the dyeing stage of blue jeans manufacturing. This step is different than most other products as the yarn for blue jeans is dyed before it is wove into a product.
This massive ball of yarn otherwise known as a ball warp is proceeded to be dipped inside a vat containing the synthetic indigo dye mixture. This process is done several times to create multiple layers of blue color on the yarn. These multiple layers of color are responsible for your blue jeans slowly fading to lighter and lighter shades of blue. Once the yarn has been dyed it is then moved to be slashed. Slashing is coating the yard with a sizing agent to create strength and stiffness. Upon completion of this process the yarn is able to be woven together to make a complete cloth.
The dyed yarn is placed onto mechanical looms and woven. The freshly woven denim cloths is passed on and cut into the correct patterns then sewn together in a particular style in order to create the blue jean design. The process of cutting the fabric into pattern is completely with the aid of a high-speed cutting machine. This allows large quantities to be completed in a short amount of time, also leaving less error in the shaping and sizing of the blue jean pattern. The actual process of sewing the materials together to create a finished product is still done by human hands. This sewing is done in an assembly-line fashion to boost speed and productivity. Doing this also creates a different level of perfection as the human eyes can quickly tell if a certain blue jean is being done incorrectly.