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Saturday, 16 February 2013

The History of Blue Jeans and Denim



The story goes that “jean” derives from the word Genoa. It refers to the material that sailors from Genoa used in their pants. This was a coarse cotton-wool and/or linen blend. It originally came from Italy, and is evidence of the custom of naming a material for its place of origin. By the late 16th century, jean was already being produced in Lancashire, England. The composition eventually evolved to 100% cotton by the 18th century.  Both fabrics( denim and jeans) grew in popularity, denim being the stronger and more expensive of the two. The major difference between them was that denim was woven with one colored thread (the warp) and the other white (the weft), while jean was woven with two colored threads.
By the late 19th century, weavers in America were making twills in the same fashion as the European denim, adapting to the more readily available and locally produced cotton fibers. The material had a reputation for being very strong and not wearing out quickly, in spite of many washes.
Jean and denim remained two very different fabrics, and were used for different types of clothing. Denim was used mainly for workers clothes and jean for lighter clothes that did not have such high durability requirements.
So, how did the modern term “jean” come to refer to pants made out of a fabric called denim? The answer lies in the story of Loeb (Levi) Strauss. This is where the modern history of blue jeans starts.
Mr. Strauss came to America from Bavaria in 1847 with his mother and two sisters. They arrived in New York where his half brother ran a wholesale business selling, among other things, various types of fabrics and clothes. After working for his brother for a few years, Levi decided to travel west to San Francisco and partake of the benefits of the Gold Rush.
His original intent was to open a branch of his brother’s wholesale business. Levi did this diligently for the next 20 years, acquiring a reputation as a quality supplier to small stores throughout the West.
His fate and the history of clothing would change forever when in 1872 he received an offer from Jacob Davis, a tailor from Reno Nevada. Mr. Davis, in order to improve the durability of the pants that he made for his clients, had been adding metal rivets to the highly stressed seams. The idea was successful and he wished to patent it. Lacking the money to do so, he turned to Levi for financial backing, and of course, a partnership. In 1873, the new partners received a patent for “an improvement in Fastening Pocket-Openings”, and thus the history of blue jeans as we know them begins.
They started making “waist overalls” out of denim and cotton duck. They knew that the selling point of the new product was its durability, making it more appropriate for work clothes. Eventually, the cotton duck was dropped for the more comfortable denim.
By the 1920’s “waist overalls” were the most widely used worker’s pants in America. The name “jeans”, however, was not officially adopted until the 1960’s. Levi Strauss and Co. recognized that it had no choice, as this was what the product was being called by the young, leisure loving teenage boys. The history of "waist overalls" continues as the history of blue jeans. "Jeans" is now generally understood to refer to pants made out of a specific type of fabric called "denim".
50s Fashions: By 1950, Levi’s began selling nationally. Everybody now had a chance to wear a pair of original Levi’s Jeans, as they were now called. Other brands emerged, such as Lee Coopers and Wranglers, each with its own particular fit.
The rise of the popularity of jeans after the WWII can greatly be attributed to the influence of the film and music industry. This effect is not hard to understand, as even today fashion trends are greatly influenced by what highly publicized celebrities choose to wear. The history of blue jeans in the second half of the century can be traced to the celebrities that used denim.
In the 1960’s and 1970’s they were embraced by the hippy movement, and the trend to personalize and embellish jeans began. The history of blue jeans gets linked to the downfall of communism! Behind the iron curtain, jeans became a symbol of “western decadence” and individuality and as such were highly sought. Hip-huggers, bell bottoms, baggies, and elephant ears were the craze. Pre-washed jeans were first marketed.
In the 1980’sthe history of blue jeans was transformed forever. Denim debuted as high fashion. The term “designer jeans” was coined. Sergio Valente, Jordache, Calvin Klein were amongst the first to create slimmer, tight, butt hugging jeans.
In the 1990’s, although denim was never completely out of style, it did fall “out of high fashion”. Denim was still hot, but the new generation turned to other fabrics as well as other styles (khakis, chinos, combat, carpenters and branded sportswear).
The new millennium: All borders are down. Denim is everywhere. Denim is back on designer’s catwalks, on accessories, home collections, and designer jeans by the hundreds of labels. Price barriers have been broken. Washes and finishes, embellishments, destroyed and distressed jeans, ultra low rise jeans, the palette available to designers offers limitless possibilities, and the market appears to never bottom out. The history of blue jeans goes on.

The History of Denim



Denim at its most basic is a simple cotton fabric – but it’s created one of the most enduring and beloved fashion items in recent history – jeans. Denim inspires debate and passion amongst designers and fashion lovers, and there is equal passion in the debate around its beginnings.

The first use of denim as a cotton material dates as far back as the 17th century, when it appeared in upholstery, work pants and awnings, ship’s sails and cowboy jeans – the fabric of hardworking, honest labor. The origin of its name is widely believed to be an Anglicism of the French for ‘serge de Nimes’ – the serge fabric, made in Nimes, France.

By the 18th century, denim cloth was made only of cotton and was used to make strong and durable men’s clothing – valued for the way it lasted repeat washing. The famous Levi Strauss Company was created in 1873, with a patented denim jeans process featuring the famous Levi metal rivets. Levi had noticed that miners in the San Francisco gold rush needed strong and sturdy work pants, and he worked with his partner Jacob Davis to produce their patented designs of ‘waist overalls’ with copper rivets, in the famous blue denim, and also duck – which was a thick material which fell out of decline in favor of denim, as it was said to feel like ‘wearing a tent!’. These overalls proved to be a great success – and Levi and Jacob moved into producing jackets and outwear, as well as muslin shirts. When Levi Strauss died in 1902, he passed the successful business to his nephews.

Over time, demand outstripped supply and the Strauss’ needed to find a new denim mill, as competition from the South was causing their New England supplier to struggle. By 1915 it was buying most of its denim from North Carolina and by the 1920s Levi’s waist overalls were leading the men’s’ work pants market in America. This only increased further in the 1930s, when the era of Hollywood westerns arrived, and Levi jeans became a high status fashion item, associated with the freedom and individualism of cowboys and the glamorous actors that played them. Heavy advertising spread their popularity across America and overseas.
In the Second World War, American GIs were known to take their favorite jeans overseas for action, to keep them safe! After the war, Denim pants became increasingly associated with leisure activities of American people. Zippers began to be used in the 50s, and jeans became associated with teenage rebellion being featured in films of the time, and banned from many schools and colleges. During this same decade, the company began to export its products worldwide as word spread. This new youth market was reflected in the name ‘jean’ being formally adopted by Levi’s in the 60s, as jeans flooded Europe and Asian markets, and became a symbol of youth, ideas, individuality and leisure.

By the 70s, flares and bell-bottom jeans were king, with heavy advertising and marketing continuing to increase the market. Decorated jeans became an early craze in 70s America, making jeans the canvas material for expressing personality. In the 80s, bleached, ripped, skin tight and faded jeans came into fashion and the designer jean was born  nowadays the world’s biggest celebrities all wear jeans, and this staple item is featured in innovative new ways in every catwalk collection.

A huge range of small boutiques are producing exciting new jeans ranges – often focusing on either urban, sports, traditional or glamorous looks for both men and women. Some of the most exciting new brands are coming out of Asia, such as One Green Elephant – a Japanese company which produces fashion-forward and cutting edge jeans using a variety of new and experimental techniques. Their range features key styling attributes such as organic cotton, distressed finishes, twisted seams, reverse stitching and contrast hemming – with jeans produced in all fits from relaxed to stretch and a range of rinses and finishes. The look is very much about cutting-edge, urban living with an emphasis on youthfulness, creativity and urban nightlife.
It will be fascinating to see where these cultural emblems go next – only one thing seems certain, and that is that jeans will continue to inspire design innovation and fashion – and will never go out of fashion.

Fabric consumption


The garments manufactured in many sizes to fit for everybody. Generally they are in sizes Small (S), Medium (M), Large (L), Extra large (XL) and Double Extra Large (XXL). The quantity ratio or assortment can be any one of the following approximate ratio.
               S: M: L: XL: XXL - 1:2:2:2:1
               S: M: L: XL: XXL - 1:2:1:2:1
               S: M: L: XL: XXL - 1:2:3:2:2
As the price is the same for all these sizes of garments, the author have taken the centre size large(L) for average calculation. Generally, the quantity of L size will be higher or equal to the quantity of each of other sizes.

Men's Basic T-shirt
Description: Men's Basic T-shirt-short sleeves- 100% Cotton 140 GSM Single jersey - 1 x 1 ribs at neck - solid dyed - light, medium and dark colours in equal ratio.
Sizes: S, M, L, XL, XXL Ratio: 1: 2: 2: 2: 1
Export carton: 7 ply -120 GSM virgin corrugated - sea worthy. Cartons are to be strapped with 2 nylon straps.

Measurements in cm: (Finished garment)
Size: L
Chest - 60 cm
Length - 78 cm
Sleeve length - 24 cm
Neck rib width - 3 cm Hem - 3 cm
Patterns are generally made with the seam allowance and cutting allowance. Generally, 12 cm is added with the total of body length and sleeve length.
That is,
Fabric consumption =(Body length + Sleeve length + allowance) * (Chest + allowance) * 2 * GSM
                                                                                             10000

                               = (70 + 24 + 12) * (60 + 3) * 2 * 140
                                                             10000

                                         = 187 grams
Body & Sleeves : 187 grams
Neck rib : 10 grams (approximately)
Gross weight : 197 grams Therefore, the fabric consumption per garment is 197 grams.

Gross weight & net weight
The above weight is the gross weight of fabric. It means the weight of the fabric bits cut in tubular form without taking shapes is called gross weight. This is the consumed fabric for the particular garment. Hence costing is to be made as per this gross weight. The weight of the cut pieces after taking the shape according to the pattern is called net weight of fabric.

Garments Costing



There are two types of garments, namely woven and knitted garments. Shirt, trouser, sarees, bed spreads, blankets, towels and made ups are woven. T-shirts, sweaters, undergarments, pyjamas and socks are knits.
Costing is the deciding factor for fixing of prices and the important thing to follow in all stages like purchase, production, marketing, sales, etc. Also update knowledge about everything related to garments, is essential to make perfect costing.
Costing includes all the activities like purchase of fabrics and accessories, processing and finishing of fabrics, sewing and packing of garments, transport and conveyance, shipping, over heads, banking charges and commissions, etc.
We must be aware that there are always fluctuations in the costs of raw materials and accessories, charges of knitting, processing, finishing, sewing and packing, charges of transport and conveyance. The method of making costing will vary from style to style. As there are many different styles in garments. Hence let us take men's basic T-shirt style as example which is in regular in use.
To find out the costing of a garment, the following things should things be calcuated:
  • Fabric consumption.
  • Gross weight of other components of garment.
  • Fabric cost per kg.
  • Fabric cost per garment.
  • Other charges (print, embroidery, etc).
  • Cost of trims (labels, tags, badges, twill tapes, buttons, bows, etc).
  • CMT charges.
  • Cost of accessories (hangers, inner boards, polybags, cartons, etc).
  • Cost of a garment.
  • Price of a garment.

Friday, 15 February 2013

A revolution in denim

Realizing the universal love for jeans, Uniqlo continues to strive to bring out the most ideal designs and denim fabrics for jeans that will capture the attention of jeans-lovers all over the world.
Made of 100-percent cotton, the Uniqlo Regular Fit Straight Jeans, which the company calls “classic denim,” is made from a high-quality fabric.
Uniqlo’s bleached jeans have been delicately processed to exude a naturally worn look. This is achieved through a processing technique that makes the jeans look natural and fit the wearer flawlessly.
The brand’s principle on denim fabrics is not limited to cotton. Its line of jeans for women, including the Powder Soft style, epitomizes Uniqlo’s desire to create jeans that can be worn with great comfort.
With the advent of stretch denim, women now desire a pair of jeans that boasts a perfect silhouette, with a shape that flattens the legs and hips, and which can be worn with utmost comfort and absolute freedom of movement.
Uniqlo’s High Rise Straight Jeans, which erased the notion that denim fabric is rough, give the wearer the same level of comfort as the Powder Soft line. The High Rise Straight Jeans also provide wearers with a new standard of look and feel.

Denim Garment Design Process

Denim Garment Design Process
When designing denim apparel, the designer will usually start by hand drawing or electronically rendering sketches of the clothing to create a collection. A collection usually has several pieces of clothing that share common characteristics and tell a story to both the buyers and customers.
After this, the designer orders cheap mock-ups of the designs so that he can see the garment characteristics in real life. He will show these rough sample garments to others in the company who handle washing and detailing so that they can begin to plan fabric dyes and treatments for the apparel. They will also nix any designs that they do not wish to manufacture.
Mega-retailers like The Gap, who only sell products internally, will at this point compile a "look book" for store owners with hand-drawn pieces so that they may start buying. Non-chain denim-wear lines allow buying after the second set of polished, finished samples is produced.
Denim Clothing Manufacture
Once the garments have been finalized and selected, the pattern maker creates manufacturing patterns for production. These are then sloped, or sized, to accommodate various body measurements. Often, a jean or denim garment will use an old pattern that has sold well, rather that creating a fresh pattern.
The denim fabric is brought into the factory, and the cutting process begins. From there, the jeans are stitched by hand, or completely by machine. Interior labels are added before the waistband is stitched. The denim garment is still the old-fashioned indigo jean fabric with no conditioning or distressing. It reaches the conditioning stage of the assembly process, where the apparel is battered, beaten, painted, scrubbed or acid-treated to achieve the desired wash. After this, machines then add rivets, outer branding labels, or any other specialized trims.
Tagging and Distribution
At the end of the process, the denim garment is tagged with pricing and brand identification information, folded and packed in a plastic bag. These finished denim products are shipped out to stores for sale or stocked in warehouses for future distribution.
Depending on the company, distribution can be a simple process or may be tightly controlled. Premium jeans companies often label individual garments with serial numbers and can tell right away if apparel is authentic or has been stolen because of this code. Often, production creates an overstock of apparel that can be sold to discount store jobbers; alternately, surplus denim clothing might sell at a sample sale or outlet center.