Behind the Scenes: COTTON YARN FOR DENIM

Originally denim jeans were made from 100% cotton and in spite of jeans now containing other fibres the main component is still cotton.

After the cotton processes, the cotton is then spun on an open end or a ring frame.  The latter creating a superior quality yarn.

These little drawings give a birds eye view of the spinning and warping processes which are magnified in the photographs.

The above drawing depicts an open end spinning frame whilst the photograph shows a modern ring spinning frame capable of producing thousand of spindles per day.  A small denim plant can manufacture around 20 million yards of denim per annum and a big plant up to 120 million. Therefore such mass cotton spinning is very much required for today's mass manufacturing requirement.

Over the coming weeks we will share some of the old denim making processes which were much more of a craft than those of today.

Workers in Pakistan going home after a day in the factories.  A colourful local scene in Lahore.

Cotton and denim is delivered in heavily decorated trucks in Pakistan. Each driver takes great pride in his truck paying artisans to personalise the truck under his watchful eye.

BEHIND THE SCENES: Making denim fabric.

From delivering the cotton bales to dispatching the finished denim fabric.

This charming drawing by Danny Southern late of Burlington Denim in North Carolina depicts the whole process of making the denim fabric.  Although the equipment has been modernised and some added the processes remain the same today as they were in the late 1800's.  Over the coming weeks we will take you though the journey of Indigo denim from cotton through original indigo dyeing to the finish jean.



Cotton fields ripe for picking 



Raw cotton bales are stored outside during the dry months in Pakistan.  Which is one of the biggest manufacturing hubs for the supply of denim and jeans to the USA and Europe.

The following charming images depict the flow of the cotton from the opening process through to drawing.

Local construction workers working on site at a Pakistan denim factory.