PRODUCTION PROCESS OF DENIM FABRIC
Cotton: Living Matter
The open end yarn exits the rotor and is wound onto a package similar to that produced at the winding process for ring yarn. Open end spinning is used for both filling and warp yarns. Yarns being used as filling are then sent directly to weaving, while yarns used for warp yarns are sent to the next process called warping.
Weaving Room: The weaving room is a highly spacious area, especially engineered to enable a correct and ordered movement of the beams. Each loom has a suction intake that removes any dust and filters it through a special filtration room. The room also has a dust removal system with air circulating 30 times per hour, in addition to blowers and cleaners that keep the room and looms constantly clean. Each loom has an online microprocessor which transmits data to a central computer for production and quality control.
Dyeing: The unique feature in the manufacturing of denim fabric is the dyeing of the warp
yarn through a long chain Indigo Dye Range. The logs of yarns from the warping process
called "ball warps" are loaded at the entry end of the range and are processed
through a series of boxes which contain dye to build the shade and through boxes that
rinse the yarn of excess dye. Between boxes, the ropes are exposed to air in a process
known as skying, where oxidation or fixing of the dye takes place.