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The Entire Manufacturing Process of a Pair of Jeans

A roll of indigo denim is steadily transported into the workshop by a forklift, marking the official start of the journey to create a pair of jeans. This 50-kilogram roll of fabric, made from Xinjiang long-staple cotton, undergoes three meticulous processes: spinning, dyeing, and weaving. The faintly visible slub texture on the fabric is a natural quality formed by uneven yarn thickness, and it is also the exclusive fabric selected by the purchasing team after repeated comparisons from 30 samples.

In the cutting workshop, the fragrance of fabric fills the air. An experienced master spreads the pattern flat on the unfolded denim and quickly outlines the contours with a chalk pen. The blade of the CNC cutting machine moves up and down at a frequency of 10 times per second, cutting 10 layers of fabric at the same time, resulting in smooth, burr-free edges of the pant pieces. "The error must be controlled within 0.5 centimeters; otherwise, the trouser legs will be skewed," he says while carefully measuring with calipers. These calloused hands have cut pant pieces over the past 20 years, covering an area equivalent to 3 football fields.

In the sewing workshop, the clatter sound of sewing machines echoes like a passionate industrial symphony. The female worker at the side seam station moves her fingers nimbly, using a double-thread stitching process to perfectly enclose the edges of the two layers of fabric, with a stitch density as high as 3,000 stitches per meter. "This position tests endurance the most; even a missing stitch can lead to splitting," she says. A photo of her family is pasted on the board in front of her, and the pedal under her feet has been worn into a deep groove. The topstitch at the waistband needs to be inclined at 45 degrees, with a stitch distance error not exceeding 0.3 millimeters. Quality inspectors check each one with a magnifying glass, and unqualified products must be unpicked and re-sewn.

The washing workshop can be called the "dressing room" of jeans, with 30 huge washing tanks steaming with heat. In the enzyme washing tank, the fabric is soaked for 6 hours, and protease breaks down the fluff on the fiber surface, making the fabric feel soft. In the stone washing tank, pumice stones collide fiercely with the fabric, grinding natural whisker patterns on the knee areas. The master regularly takes out the fabric to check the effect, ensuring that the pattern similarity of each batch of products reaches more than 90%. The final ozone treatment process can improve the indigo color fastness by 4 levels, preventing severe fading even after 50 machine washes.

In the pleating workshop, the pressure plate of the high-temperature pleating machine reaches 180℃, pressing the trouser creases straight and stiff. After cooling, it undergoes 24 hours of setting. The worker at the button-attaching station holds the leather label with his left hand and presses the switch with his right hand. Brass rivets are embedded into the fabric with a pressure of 3 kilograms, and each button must withstand a 5-kilogram pull test to be qualified. The embroidery pattern on the back pocket is precisely controlled by a computer, and the brand LOGO embroidered with 2,000 stitches has uniform lines, just like printed.

The final quality inspection link is like giving the jeans a "physical examination". Workers will spread the jeans flat on a light box, carefully checking for skipped stitches and stains; use a tension meter to test the seam strength, which must withstand at least 30 kilograms of tension; and also put on sample pants to do squats, splits and other movements to ensure free movement when wearing. Qualified jeans are classified by waist circumference and length, put into dust bags, and neatly stacked on pallets. From the fabric roll to the finished product, it goes through 28 processes, takes 36 hours, and embodies the efforts of 12 workers.

When this pair of jeans is hung on the store shelf, every pattern and button on it carries the stories from the factory - the persistent pursuit of precision and the craftsmanship full of warmth, making this daily clothing have a significance beyond itself.

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