Why Does Denim Bulk Production Often Have Color Shading

In denim jeans production, color shading or color variation is one of most headache issue for the denim suppliers. And indigo color shading is often the main reason that buyer reject the goods or quality claims. How to maintain the denim color consistency and control batch variation is always challenge for denim factory.

Unlike the reactive dyeing, denim indigo dyeing is basically physical process. Indigo dye doesn’t dissolve in water on its own, you need to use the chemical agent to make it soluble into water then get onto the yarn or fabric, after dip the fabric and then dry the fabric in the air, the indigo dye oxidizes and turn back to the insoluble indigo again, setting on the surface of the fabric.

This special continuous dyeing process is affected by the natural environment and oxygen levels in the air, so even with the same dye formula, the fabric may have different dye lot variations. Not even say the jean need go through complex denim washing processes, the color bleaching and oxidation every time will increase the color instability.

Causes of Color Shading in Denim Bulk Production

– Oxidation inconsistency: variations in oxygen level and duration of air exposure

– Washing Temperature

– PH of the Water Purity

– Fabric Quality: inconsistent yarn tension or weaving density

– Chemical purity: The quality of chemical agent used

– Variability of manual operation: human error when operating

Batch color variation is unavoidable,not only the denim fabrics but also the finished denim garment. However a good denim manufacturer will control the batch color variation within a acceptable range, ensuring the color discrepancy is unnoticeable visually

How to Prevent Color Shading in Denim Production

– Standardize the denim dyeing and washing parameters

When in denim washing process, washing mill must strictly monitor the PH levels, temperature and chemical concentration, make sure the parameters is same as the standard sample. And also maintain the workshop humidity and airflow, avoid the effects of oxidation. This is especially for the light blue colorway, the speed of indigo oxidative discoloration is much faster than you know.

– Testing the fabric color and adhesion

Before garment sewing process begins, other than testing the fabric shrinkage, you must also must test the color of each roll of fabric to see the batch color variation. This can prevent color discrepancies on single pair of jeans, also can see the if any potential issue during bulk washing. It is major quality risk if not testing the fabric color. Because the color adhesion of the denim fabric can’t be see by eye before washing.

– – Run Washing pre-production lots(washing first lot)

When order units is big, it definitely need to see the first lot before starting bulk washing process. Try a small batch first see the color, record all the influential parameters and judge if need some adjustment. Ensure the washing parameters is correct. During the process also need check the color when each batch are taken out from the laundry, and take immediate action once need adjustment

– Use high quality chemical agent

Sometimes even with the exact same parameters, formulas and machine, the finished denim jeans still show difference, and this is probably caused by quality of the chemical agent.Premium chemical reducing agents keep color fading consistent longer and more even finishing, while poor ones have no such stability and will cause color peeling plus impurity precipitation. 

Conclusion

Denim washing is an extremely complex process. Even with strict standardized processes, inconsistencies may still occur—but this is precisely what makes denim unique and one-of-a-kind. 

Reego is professional denim manufacturer with rich experience in denim washing. Partnering with and denim expert like Reego will help you make the right decision in denim purchasing and quality control.

How do I create my own brand of clothing?

How jeans is made?

How to avoid the main problem when producing denim products?

FAQs

1.How long will it take to make one sample?

In Reego practice, it is not only sewing. We need to select the most suitable fabric and test the shrinkage, try the washing color to ensure the sample meet the requirement. We also do final inspection of sample details before sending, to sure the sample you get is perfect.

2.What is the Minimum Order Quantity (MOQ)?

Moreover,we always strive to lower the waste through the whole production process , as part of of our commitment to sustainable production. To support the new brand, we offer flexible trial order solution to meet their small batch needs.

3.What is the most important in denim production at the beginning?

In Reego practice, communication is essential. Before staring, our design and pattern master will review all the technical details and discuss any difficult point, that will help minus the potential errors and ensure the fit, color, styling is wanted and this jean is manufacturable.