Jeans 

Fabric Information

PRODUCTION PROCESS OF DENIM FABRIC

Cotton: Living Matter
A first product is the result of a careful selection of materials. The cotton used for production is purchased in the United States, selected to meet the qualities most suitable for manufacturing denim fabrics. Each bale of cotton is tested and selected in our laboratories to make sure that the highest quality standards are maintained

Open Ended Spinning:
For Open End Yarn, the roving, spinning and winding processes are combined into one process. The drawing sliver is fed into the open-end frame where a combing roll parallels the fibers. The stock is then fed into a rotor that spins the yarn with a combination of air and rotation of the rotor.

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.
At the end of the range, the yarn is passed over steam heated dry cans for drying. Process controls are located throughout critical components of the Indigo Range and processing is monitored and controlled. When the yarn leaves the dry cans, an in-line color monitoring system measures its shade and provides immediate feedback.

Quality Control:
Continuous check points for quality control are conducted during every phase of the production process, from the fiber opening to spinning and weaving every piece of fabric is also subjected to a visual inspection and graded according to international standards for quality and shade so that it is unnecessary for the customer to re-inspect the fabric. Before leaving the factory, every piece of denim must meet the stringent quality standards for width, weight, tensile and tear strength, shrinkage and response to the stone-washing process.

California
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