#1 SELECTION OF COTTON FIBRES
It all starts with the selection of high-quality cotton fibres. The cotton varieties chosen guarantee the durability and strength of the denim fabric. The fibres are carefully sorted to remove impurities and ensure uniform quality.
#2 SPINNING
Selected cotton fibres are spun to form strong, even yarns. Spinning is a process in which the fibres are stretched and twisted to create yarns that will be used to weave the denim fabric.
#3 DYEING
Dyeing is a crucial stage in the manufacturing of denim jeans. The cotton threads are dipped in vats of indigo dye to give them the characteristic blue denim hue. This indigo dyeing process is repeated several times to obtain the desired shade of blue.
#4 WEAVING
The dyed cotton threads are then woven to create denim's characteristic serge pattern. The serge weave is a diagonal pattern that gives denim its unique texture and strength. This weave also allows the jeans to retain their shape and offers a certain stretch for greater comfort.
#5 PRETREATMENT AND WASHING
After weaving, the denim undergoes pretreatment to remove excess dye and make the fabric softer. The denim is then washed to obtain different finishes, from raw (unwashed) denim to faded or distressed denim. Washing can involve various techniques such as stone washing, laser washing or enzyme treatment to create special effects on the fabric.
#6 CUTTING AND ASSEMBLY
Once the denim has been prepared, the fabric is cut into different pieces in line with the denim pattern. The different parts of the jeans, such as the legs, pockets and waistband, are assembled with special seams to ensure the garment's durability.
#7 FINISH AND DETAILS
After assembly, the jeans undergo finishing to reinforce the seams and high-tension areas to keep the garment strong. Details such as metal rivets on the pockets, button fastenings and leather labels are added to give the jeans their distinctive look.
#8 QUALITY CONTROL
Before being distributed to shops, each pair of denim jeans goes through a rigorous quality control process. Manufacturers check the strength of the fabric, the quality of the seams and finishes, and compliance with the design specifications.
