Jeans Manufacturers for Growing Denim Brands

Designing a pair of jeans that stands out seems easy at first, until you dive into the specifics. Fabric weight, yarn, fit, pocket shape, stitching, hardware, wash and color all have an impact on the final product. For a fashion brand, selecting the right jeans manufacturers means choosing a manufacturing partner that will follow through the details and maintain the same quality standards as the brand develops.

Start With the Right Denim

Fabric generally is determined first. Calico or light weight denims can be softer in hand and move with less abrasion, whereas the heavier weight denims achieve a stronger structure with a stiffer hand. A number of factors along with the weight of fabric can impact on fabric micro-variation seen when the denims are washed. CottonWorks states that; ‘the fabric‘s nature is defined by the yarn, the indigo, the weave, the design of the garment, the washing process, and the finishing.

This is why a brand cannot select the denim simply based on the fabric, it must be tested in the factory for fabric weight, stretch, shade, shrinkage and behaviour after wash. A small washing test can expose any faults that would not be apparent in a raw fabric sample.

Build the Fit Before Bulk Cutting

Next is pattern development. A pair of denim can appear to be a whole different style when a brand varies the rise, thigh width, leg opening, pocket placement or waistband shape.

If the development process begins well, with good measurements and a good style reference. The factory develops a sample, then it washes it when the design involves garment washing, and it re-measures. It is important because washing alters the size and look of denim.

Brands have to consider the customer they want to target. Wide-leg jeans will require a different proportion to slim fit. A streetwear branded line might prefer a relaxed fit at the seat and a longer rise whereas a classic denim company might opt more slim and clean.

Sewing Gives Jeans Their Structure

Once the pattern is fitting, the factory begins production through cutting and sewing. It is important to realize that the little construction details can greatly change the final appearance.

All of these in addition to pocket placement, construction of the waistband, belt loop construction, fly construction, seam allowance and stitch density must be considered during construction. The back rise must also be monitored as it impacts finished fit and overall look.

Hardware provides further detail. Needles, rivets and zippers should complement the cut and perform adequately during everyday use. Rivets can be used to strengthen areas through- and under stress and branded hardware can also contribute to the overall visual strength of a jean.

Washing Changes the Character

No washing is another common reason for the greatest visual differentiation between different denim styles. Raw denim samples can appear drastically different after a factory has processed it by means of a wash.

Stonewashing used to cause fading and softer hand. Enzyme washing alters surface and enhances highlights. There are other processes to create more contrast, lighter shades or special surface effects. CottonWorks included stonewashing, enzyme, decoloring, discharge, (bleeding), tinting, sanding and other processes in finishing of denims.

The wash team needs a definite reference as the result may alter with slight variations in; time, temperature, chemicals, abrasion. A factory must have at least 1 wash trial before stepping into mass production.

Distressing Needs More Than Random Rips

Distressed jeans are in need of even further direction. A few holes may appear simple, but all of the detail that is involved with them, including their placement, size, shape and fading.

Hand sanding may produce whiskers and highlights around the legs, hips and pockets. Plus of course other deconstruction methods can produce much more extreme contrast or area-specific color variation. CottonWorks include hand sanding and discharge as Deluxe denim finishing techniques.

The secret is consistency. A lot of sweatshops may want the same level of destruction on 100‘s of trainers, and so need clear images to tell stylists. If there is no reference each trainer will be a different breed of distressed.

Quality Checks Should Follow the Whole Process

Quality assurance must occur at early stages in production not at end. Workers can monitor the quality of denim before it gets cut, supervise stitching, and re check the after the washing process.

Measurements require special attention. The factory needs to measure the waist, rise, hip, thigh, inseam and leg opening to the approved measurement chart. The washers need to check the seams, stitches, pockets, zippers, buttons, rivets, fault fabric, wash consistency and the color.

According to CottonWorks, the factories have the chance to screen the garments before wash due to the possibility of open seams to creating issue during the wash. A second chance to screen the item could be used before shipment.

MOQ Depends on the Project

There are different minimum order quantities for different factories. More crucially, the MOQ can be different depending on the fabric, wash, hardware, color and the working setup.

A handful of manufacturers now have low-MOQ denim programs around 50 pieces per style though some have higher minimums.

A smaller production run might be required for a new style, testing for fit etc. Too large a minimum may be required if a Production order is needed for a college collection (hundreds or thousands of pieces). Good factories will talk through production plans rather than just offering a fixed MOQ.

From Sample to Bulk Production

An effective jeans program normally begins with well defined tech packs, fabric, measurements, trims, wash references, labels and packaging. Once these are determined, the factory produces the sample and completes the execution with the brand.

Once the sample is approved by brand, factory can start to produce the production plan. And the production plan need to include: fabric, cutting, sewing, hardware, washing, checking, packing and shipping.

As for JiuvelWear, it is also closely tied with the total customized clothing manufacturing service of Dongguan Jiuzuo Clothing Co., Ltd. The team cooperate with brands in fabric procurement, sample developing, manufacturing, inspection etc.

At the end of the day, however, selecting a jeans producer is not just about price. If a factory is unable to manage fit, fabric, washing, measurements and quality from one run to the next, a lower unit cost is meaningless. Brands looking to develop a collection of dependable denim should seek a producer with a good knowledge of the whole process one who can take a design reference and realize it.