Technology of Denim Production: Part-I (Yarn Manufacturing Techniques for Denim)

The term "Denim" has developed from the city of Nimes in France denim was produced for the first time. In the nineteenth century heavy cotton fabrics were produced in the Rhone Valley region of France. These fabrics were known as tissue de Nimes and Blue de Genes. The term denim and jeans derive from these designations.


The classical denim is a heavy fabric made from 100% cotton andwoven from coarse indigo dyed warp and grey undyed weft yarn. The traditionaldenim is hard-wearing, high density fabrics with a high mass per unit area anda 3/1 or 2/1- twill weave construction.


Denim is available in attractive indigo blue shades and ismade for a variety of applications and in a wide range of qualities and shades.Classical denim is made from 100% cotton dyed with Indigo blue shades. Besidesclassic indigo blue, denim is also dyed in other fashion shades and colors, themost popular being black denim. Denim is comfortable, fashionable, affordableand durable and popular in all the age group. Denim is available in differentweight ranges from 6 16 oz/sq yd which is categories as light denim 10-12oz/sq yd., heavy denim 14-16 oz/sq. yd.

Yarn Quality


In order to produce good quality denim, the yarn qualityused for denim production should be optimal. In rope and slasher dyeingmachine the passage of yarn is very long. Hence it is necessary to control thelapping of yarn in the passage of yarn, otherwise bands of high and lowdensities will be formed in the yarn, which ultimately cause shade variation inthe fabric. This leads huge loss of fabric. Therefore the TM of the yarn is tobe appropriate to avoid any snarling of yarn during running through thepassage. The yarn should be free of weak place, to avoid any breakages duringdyeing. Long slub, thick and thin places in the yarn may leads to prominentfabric defects in the fabric, as denim is a contrast fabric made of indigo bluewarp and grey weft yarn. The weft yarn hairiness should be low, otherwise highyarn hairiness and major variation in yarn hairiness shown weft bands which isa major fabric defects. Higher yarn neps may also cause serious fabric defects.



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About the Author:


Theauthor is Manager (TQM) at Shri Lakshmi Cotsyn Limited, UPSIDC IndustrialArea, Malwan, Dist. Fatehpur, UP