Denim fabrics are in demand for casual wear due to their flexibility and comfort during body movements. They are also preferred for their shape retention and low abrasion resistance properties.

The denim sector is constantly advancing its fabric properties to meet these requirements. One of the ways to do so is by using different fibers and functional yarns to contribute to fabric performance.

Increased Comfort

Suppose you’re an avid biker, hiker, or boater and want to be comfortable in your clothes while on the go; you’ll appreciate the flexibility of wearing stretch denim. Not only do they conform to your body immediately, but they will only wear out slowly as non-stretch jeans.

For this reason, many denim companies have switched to using dual-stretch fibers for their jeans. These fibers blend polyester and spandex, known for their elasticity and freedom of movement.

High-stretch textiles are used in patented technologies like the LYCRA dualFX technology to keep their shape and fit over time. The material is engineered to have a small amount of stretch but high dimensional stability so that jeans hold their shape even over long periods.

One of the most popular features of stretch denim is its elasticity, and it’s essential to control the elasticity in the fabric so that it doesn’t cause deformities. Unfortunately, too much elasticity can also lead to problems like wrinkles and a decrease in the lifespan of the clothing.

Currently, the main elastane-based denim fabrics are produced by inserting elastane fibers in the weft direction during weaving. However, there is a gap in the market for materials that can combine excellent performance with low growth and shrinkage, which will help to improve the durability of the denim. To overcome this problem, this study aims to develop a denim fabric to meet these demands.

Increased Durability

There are many benefits to wearing dual stretch fibers for denim. In addition to being more comfortable and having a better fit, these fabrics also have improved durability.

The elasticity of denim fabrics is vital to their performance because it allows them to maintain their shape over time. However, this can be problematic when the material grows or shrinks during wear. This can result in poor-fitting jeans, product returns, and dissatisfied consumers.

For this reason, it is essential to find ways to keep the growth and shrinkage of elastane-containing denim fabrics at a minimum while maintaining the desired elasticity. This can be achieved using alternate fibers with different elastane properties and ratios.

Several studies have been conducted on this topic. Some of them have shown that the elasticity of denim fabrics increases when the elastane ratio is increased. Other researchers have found that denim fabrics’ growth or permanent elongation values decrease with increasing the elastane ratio.

In this study, denim fabrics were woven with dual core-spun yarns. These fabrics were evaluated for their performance according to standard test methods. The tests included breaking force, breaking elongation, tear force, elastic recovery, wicking rate and water absorption rate.

All the response variables were analyzed in both warp and weft directions. The results showed that filament fineness and elastane draft parameters were significantly related to the breaking force, breaking elongation, static tear force, elastic recovery, vertical wicking rate and water absorption rate of denim fabrics.

Reduced Waste

As the global denim market grows at a compound annual growth rate of over 2%, waste generation also increases. Using sustainable technologies and recycling systems is crucial in managing denim waste.

Dual core-spun yarns are an effective solution for improving the mechanical properties of a denim fabric without compromising its softness and comfort. These yarns can be designed with different core-spun properties by combining filament and elastane in the yarn core.

This study produced denim fabrics with elastic dual core-spun yarns, different elastane draw ratios, and filament types in the weft. The effects of elastane draft and filament fineness on the breaking force, static tear force, elastic recovery, vertical wicking rate and water absorption rate of these denim fabrics were studied statistically.

As expected, incorporating a filament in the yarn core leads to a higher breaking force. Furthermore, increasing the elastane draft also improves the breaking elongation of these denim fabrics. Compared to single-core/elastane yarn, these dual-core yarns perform much better in all aspects, including strength, elasticity and wicking rates.

Increased Sustainability

With denim becoming a global fashion icon, it’s no surprise that shoppers seek more sustainable options for their favorite jeans. As a result, many textile companies are embracing new eco-friendly innovations that reduce waste throughout production.

In addition to using renewable energy and clean chemistry, some companies use green finishing machines to eliminate harmful water usage and air emissions. These innovations helped to keep 494 million cubic feet of water from being polluted last year alone.

The fabric is lightweight, highly breathable, and comfortable against the skin. It’s also designed to reduce water and energy consumption while retaining the classic look and feel of denim.

Younger consumers who value sustainability are driving the move towards more environmentally friendly innovations. The results of this movement have led to an increase in the number of synthetic fiber manufacturers focusing on producing high-performing, eco-friendly denim fabrics.