Friday, November 10, 2017

Future Trends in Denim Production

Denim is a sturdy cotton warp-faced textile in which the weft passes under two or more warp threads. Denim is a hard and durable warp faced 3/1 twill cotton fabric, woven with indigo dyed warp and white filling yarns, having weights of 14½ ounces per square yard. Among all the textile products, no other fabric has received such a wide acceptance as denim. It has been used extensively by people of all ages, classes and genders. It has been in use for over a century in the clothing industry, especially in the manufacture of overalls and trousers for hard labor, which has demonstrated its durability, which along with its comfort made denim jeans extremely popular for leisure wear, too. From the seventeenth century to the present day, denim has been used for making trousers, upholstery and awnings, and has been found in museums, attics, antique stores and archaeological digs. It is also considered as the fabric of hard work, expression of youth rebellion and the favorite of American cowboys.

Denim has had an incredible social and cultural influence on consumers and is considered an expression of youth independence, a symbol of opposition or an attitude towards life, and there is an international appeal of jeans among all age groups.

Production of denim:
Production of denim is a complex process. In order to produce good quality denim, the yarn quality used for denim production should be optimal. Cotton is extensively used for denim manufacture, where the fiber quality and staple

Denim pant production
Fig: Denim pant production
length are of crucial importance. There are some processes to manufacture of denim. They are the process of making denim fabric. Yarn manufacturing, dyeing of yarns, weaving, processing and fabric finishing are the major processes involved in denim manufacturing. We have also published an article on denim manufacturing process from fiber to finishing.

Future trends in denim manufacturing:
The manufacture of denim follows the same classical principles, what has changed is the technology. As ever, cotton is still the fiber for denim, but there is a clear trend towards organic cotton and blends with other fibers. Jeans made of viscose, lyocell, polyester or lycra blends will be more popular in the future due to their soft and comfortable feel. In a similar pattern, even though indigo will continue to dominate the denim sector, other dyes offering a full spectrum of colors will increasingly be used.

In the future, indigo may be produced bio-technologically, and the current reduction techniques may be replaced by environmentally friendly techniques. The indigo dyeing technology has not much changed, but the slasher and loop dyeing processes may grow further. Modern sulphur dyeing techniques for denim will offer great savings and will improve the environmental profile of denim considerably. Similarly, the engineering of yarns and the use of automated intelligent machines will make denim weaving a very profitable business in the future.

Lots of developments are also taking place in the manufacture and finishing of jeans. It is well known that denim jeans have an undisputed role in the fashion industry. The joining techniques for the jeans are also improving with the use of automated machines, with an aim to reduce the workload and fatigue of the operators. The dyeing technologies for denim garments are also constantly adapting to rapid small scale production catering to niche markets.

In the near future, digital printing techniques will also become established in the jeans industry. Manufacturers are ever competing to develop new washing effects on jeans, most of which are having great impacts on the environment. In this sense, there is a great future for biotechnological washing of denim jeans. To further enhance the environmental profile of washing, the reduced water washing of denim garments will grow at a very high rate in the future.

Quality consciousness is also increasing in the denim garment sector, and quality control will play a greater role in future jeans production. Different finishing techniques are adding fashion value and functional properties to jeans. In the future, the functional finishes applied to denim will convert it to a technical or protective garment. Another area of future growth is the improved comfort aspects of denim garments. Even though fashionable looks are undoubtedly important, it is clear that in the future, consumers will pay for a more comfortable product.

Apart from normal denim, there are several novel varieties of denim finding applications in different industrial sectors, apart from fashion and clothing. In the future, the market for such novel products will grow and one such application is the use of denim for non-apparel products such as furniture, upholstery, automotive and home interiors, technical products, etc. It is also expected that denim insulation will be used and encouraged in future green buildings. Denim fabrics and garments create huge environmental impacts, and as a countermeasure, the recovery and recycling of denim waste will grow in the future. Also, effluent reduction and treatment in denim and jeans manufacture will become more stringent and at the same time more efficient.

The future of denim is secure and its popularity is ever growing throughout the world, but ecology and fashion will continue to be the driving factors for jeans production and marketing. In order to retain the rich tradition of denim and jeans, all possible measures should be taken to reduce the environmental impact. The future areas of growth in this direction include the use of organic cotton, eco-efficient non-indigo dyes, intelligent weaving machines, customised garment dyeing, digital printing, biotechnological as well as reduced water washings, functional finishing, non-apparel denim products, recycling of denim waste and reduction and treatment of effluents.

References:
  1. Denim: Manufacture, Finishing and Applications by Roshan Paul
  2. http://textilelearner.blogspot.com/2012/07/process-flow-chart-of-denim.html
  3. https://en.wikipedia.org/wiki/Denim
  4. http://www.fibre2fashion.com/industry-article/5128/technology-of-denim-production
You can also like:
  1. Denim Manufacturing Process from Fiber to Finishing
  2. Different Types of Denim Fabric Used in Apparel Manufacturing
  3. Different Types of Jeans for Men's and Women's
  4. Denim Garment Finishing Treatments: Types and Process
  5. Diversification and Uses of Denim Fabrics