In this post we will talk about how denim jeans are made. From the denims rolls we offer to the finished pair of pants we all own and love.

Step 1

A company determines the type of jeans they would....

like to use for the coming season in there line. The jeans can be made in thousands of fits and styles that you see in stores.

Step 2

The designer for that company orders the fabric from a supplier like us or directly from the mill for the perfect denim to match the style and fashion of the jean they would like to produce.  Denim comes in thousands of styles, shades, weights and blends to accommodate all the different styles of jeans.  There is no “BEST DENIM” or “RULES” for what must best used. What is used is what the designer determines is the best for there brand during that season.

Step 3

The designer shows the company some of the swatches possibilities and makes a decision which to sample.

Step 4

The designer typically orders some sample yardage to create a sample pair of jeans or just legs. Sample pairs or legs are created to determine which of the selected swatches will work best in production and/or used for tests.  At this time all shrinkage and wash test will be preformed on the fabric as well.

Step 5

The samples are taken to a fashion shows to determine which one will be favored. Many designers skip this step as the fashion business ALWAYS seems to be last minute, chaotic, and scrambling to get orders out in time.

Step 6

The markers are made or selected from inventory to be used to lay on top of the fabric and cut the individual pieces of the jeans. A standard 5 pocket pair of jeans has 21 individual pieces that have to be cut.

Step 7

The fabric gets laid out on the cutting table. These tables can measure from 10 to 40 feet  long and in some cases more. Once the fabric is all stacked on top of each other and flattened the marker is placed on top of all.

Step 8

A professional cutter will cut all the fabric with a electronic cutter and bundle all the individual pieces together.

Step 9

All the pieces are sent to the sewers which at a large sewing facility will move from sewer to sewer like a assembly line which each person responsible to sew there respective part before passing it along. Not only does this streamline the process but different sewing machines and/or needles are needed for sewing different parts of each jean. During this process all the buttons, rivets, zippers, are also placed on the jeans.

Step 10

Is the wash process. With so many washes available today from rinse, stone, distress, enzyme, acid, aging, coating and many others this process has to be determined by the designer to see what is best for there line. It is also very popular to skip this step and leave the jeans raw.

Step 11

Is the finishing process where all the jeans are inspected to insure quality cut and sew.  During this step all the loss tread will be cut off and any lint will be removed from the jeans.

Step 12

The jeans are sent from the cutter to the manufacturer where they attach the tags, care labels and package the jeans.

Step 13

The packaged jeans are sold to retailer outlets and other buyers and displayed on shelves for retail value.

Step 14

We buy based on the design, marketing, or some just wait they are on sale.

Follow us for a more behind the scenes look @pacificbluedenims on our Instagram.