Jeans Factory Opportunity: How to Start a Jeans Factory

The Jeans trouser is a rugged fabric in high demand. It is worn for leisure, sports, casual and official engagements. The jean trouser is usually made from denim fabric however there are a few variations.
The primary color for jean trouser is blue. The tough material was originally designed for miners and cow boys but found a place with construction workers and youths.
Top brands in the blue jeans trade are Levis and Wrangler. It takes huge capital to setup a jeans manufacturing plant. Majority of the funds is spent on purchase of equipment.
The manufacturing process uses, manual, automated and semi automated technology. Other considerations are utility such as electrical power, factory location, transportation and sourcing raw materials.
Jeans Colors
Originally jeans trousers were manufactured predominantly in blue. Nowadays you get different shades of blue, green, black, grey and red. There are white denim’s purple, yellow, and orange jeans.
  • Shades of blue
  • Green
  • Black
  • Grey
  • Red
  • White denim’s
  • Purple
  • Yellow
  • Orange jeans
Contemporary Branded Jeans
Entrepreneurs interested in the denim trade needs to remain trendy. Here are some contemporary jeans trousers worn by ladies.
Top of the crop is the Levis Wedgie Fit, Joe’ The Oliva Cropped Flare, and Slim illusion luxe Mid-Rise Skinny jeans. Others are Denim’s Distressed Boyfriend, and Banana Republic Boyfriend jeans.
More include L’agence Claudine and Gap, original Summer Flare.
  • Levis Wedgie Fit
  • Joe’ The Oliva Cropped Flare
  • Slim illusion luxe Mid-Rise Skinny jeans
  • Denim’s Distressed Boyfriend
  • Banana Republic Boyfriend jeans
  • L’agence Claudine
  • Gap, original Summer Flare.
Machines Used for Denim Jeans Manufacturing
To satisfy the huge market for Denim jeans, manufacturers use automated and semi automated machinery. There is lots of basic equipment used in the manufacturing process.
A list of equipment’s used in the production is the electronic M/C, manual M/C, feeding electronic M/C, slide cutter, and bottom hem electronic machine. Others are Kansai special, chain stitch, over lock machine, bar tack including cover stitch Kansai special.
More are eyelet hole electronic M/c, embroider, button-hole equipment, Patten sewer and fuse machine. Others are the steam/ironing, Eastman cutter, loop setter, back yoke attach, loop making, snap button, end cutter and thread rewinding machine.
You need to purchase some of the listed items in different quantity according to the plant specification.
  • Electronic M/C
  • Manual M/C
  • Feeding electronic M/C
  • Slide cutter
  • Automated cutting machine
  • Bottom hem electronic machine
  • Kansai special
  • Chain stitch
  • Over lock machine
  • Bar tack
  • Cover stitch
  • Flat lock
  • Eyelet hole electronic M/c
  • Embroider
  • Button hole equipment
  • Patten sewer
  • Fuse machine
  • Steam/ironing
  • Eastman cutter
  • Loop setter
  • Back yoke attach
  • Loop making
  • Snap button
  • End cutter
  • Thread rewinding machine.
Manufacturing Process of Jeans
Weaving the denim Fabric
A pair of jeans starts its life from a cotton field. The cotton is picked and processed into bales. Bales are separated into small tufts and inspected for contaminants.
The carding machine removes contaminants, disentangles, and straightens the cotton into cotton threads. The slivers are spoon by the spinning machines and made into yarn.
Indigo dye is added to the yarn and later coated with a starch compound to straighten the threads. White and dyed yarn are then woven together to form a bluish thread cloth. The resultant cloth is the popular denim fabric.
How Denim Yarn is made
•    The cotton is picked
•    Processed into bales
•    Bales are separated into small tufts
•    Inspected for contaminants.
•    Machine removes contaminants
•    Disentangles
•    Straightens the cotton
•    Cotton threads
•    Become yarn.
•    Indigo dye added
•    Starch compound added
•    White and dyed yarn woven together
•    Denim Yarn/Fabric.

Making the Jeans Trousers
The finishing process is applied to the denim cloth to remove lint and loose threads. It is then skewed and preshrunk stacked into layers and cut.
A cutting machine cuts the cloth into several pieces comprising pockets, belt loops, leg panels and 7 other pieces. Industrial sewing machines perform different sewing functions along the assembly line.
The 10 pieces are systematically sewn together to produce the jeans trouser. The resultant jeans is prewashed or stonewashed when applicable.
Additional techniques are implemented for different effects such as fade look, and worn-out look. The final process is pressing the jeans using an industrial iron. The finished product is packaged according to measurement, color, style and design.
How Denim Trouser is made
  • Finishing applied to denim
  • lint and loose threads removed
  • Skewed
  • Preshrunk
  • Stacked into layers
  • Cut into several pieces
  • 10 Pieces sewed together
  • Prewashed
  • Drying
  • Stonewashed when applicable
  • Ironed
  • Packaged
Choose a Niche
You need to identify your target market and stock appropriately. Write a denim manufacturing business plan and carry out a survey.
Focus on a product and market segmentation to understand your customer needs. Your plan should focus on business structure, management team, future goals and funding.
Register the Business
Incorporate the business as a limited liability company. You also need to patent a trademark for proper branding.
Secure a manufacturers license, trade license and employer tax identification number. Make sure you comply with federal labeling and safety laws.
Develop the Product
Hire jeans designers to create a trendy product. Use quality denim material and qualified staff to manufacture the jeans.
You need a large factory in an accessible area with adequate facilities. Other requirements are truck, automated/semi-automated machinery and hand tools.
Jeans are also fitted with accessories like zippers and buttons. Make sure you have a good supplier able to fill demand.
Marketing the Jeans
Manufacturers deal directly with wholesalers and major retailers. There is also a huge export market for jeans products.
You could create custom designs or mass produce a popular product. Make sure your price is affordable and competitive.
Use electronic media and billboards to spread the word. If you can hire a celebrity to model your brand then you will make more sales.


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