Denim Manufacturing Case Study

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The textile industry is one of the largest industrial sectors in Indiaand plays an important role in Indian economy.Denim production is one of the major sub-sectors in the textile industry. The denim products are some of the most highly used in textile clothing, with continuousfashion use and consumer preference, especially by young people. A recent survey by Cotton Inc1.,showed thatthe global denim jeans market is projected to grow 8 percent, from $55 billion in 2015 to $59 billion by 2021, with Latin America and Asia expected to lead the increase. The projected growth is expected to be 12 percent in Asia, 15 percent in Latin America, 10 percent in North America and 4 percent in Europe over the next six years. In 2015, close to 1.9 billion units of denim jeans were sold in the world and by 2021 yearly sales of jeans will cross two billion units. In India, Historically, denim has been one of the fastest-growing apparel fabric segments, having grown by 500 million …show more content…

The initial process of denim manufacturing consist of all common activities from mixing of cotton fiber to spinning of fibers using either ring spinning proccess or open end spinning process. Generally, denim fabric are 3/1 warp-faced twill fabric made from a yarn dyed warp and an undyed weft yarn. Normally dyed and Grey ring or open- end yarns are used in warp and weft respectively. After the spinning process, the yarn is prepared for the warp as beam in warping process. The prepared warp yarns are indigo dyed and sized with the help of two methods. (i) Threads from several back beams are combined to form a warp sheet and dyed and sized on the same machine. (ii) Threads, about 350-400 in number are formed into ropes. 12-14 ropes run adjacent to each other through the continuous dyeing unit. After dyeing, the ropes are dried on drying cylinders and then collected in a can. After that, a worker's beam is

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