There is a growing interest in the shuttle looms in the denim industry to produce the authentic denim. The Japanese and the Italians are the ones using these looms the most.
Lets take a look at how does a typical denim shuttle loom from TOYODA and its shuttle looks like:
Category: Japanese denim
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Toyoda Shuttle looms for great denim manufacturing
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The Japanese Denim Industry
The Japanese denim industry is revered the world over for its innovativeness and its capability to set trends in the Denim Industry.
It would be nice to have a look at some facts and figures relating to the Japanese Denim Industry.
Denim Exports : 2006 about 56 million sq mtrs.
2007(till march) about 15 million sq mtrs.
Jeans :80 million pairs (approx) produced in Japan p.a
:20 million pairs(approx) imported p.a
Export markets : China,Hongkong, US, Vietnam and Italy.Main Denim producing areas in Japan : The Hiroshima perfecture, The Okayama perfecture and the Mihara Area.
DENIM MILLS
KAIHARA DENIM
Produces about 36 million sq mtrs of denim p.a
Exports about 60% of production.
Offer about 600-900 items to buyers every year.(good)
Investment since 1970 – about USD 500 million.
More than 300 looms at six mills.
Strengths : Great cotton mix and Dyeing process..
Kaihara has no plans to go overseas for production as they are quite comfortable in Japan…This shows their belief in their own capability to be highly innovative ..KURABO INDUSTRIES
Currently focusing very much on Stretch fibres and are looking at
advanced versions of stretch denim by using XLA stretch yarn,Xfit
lycra and T400. This is to take advantage of the Skinny Jeans
fashion that is currently still strong.
Developments 2006-08 : Emphasizing on the Ocean BLue colors under the Ultra Marine
Blue Brand name.
:’Wave’ – A line developed from a specially designed slub yarn .
:’Air Spinner’ – third line that features very soft denim.NISSHINBO INDUSTRIES
Capacity : About 12 million sq mtrs p.aDevelopments : As per the marketing manager of Nisshinbo – ‘Masanharu Tanaka’
the NEW TREND would be a return towards NATURAL LOOKS. This
would mean that innovative looks using Indigo and other yarn
dyeing material.
:Liquid Ammonia Treatment: Nisshinbo is also know for the
development of the liquid ammonia treatment of Denim Fabric. The
denim fabric is dipped in liquid ammonia (about -40 degrees C)
which enables it to regain its original shape , thus giving back
natural softness to the fibre. One of its five ammonia treatment
plant is used for treating Denims.Other developments in the Japanese denim Industry :
The DUCK TEXTILE CO. has introduced a JERSEY DENIM – a denim made of knit fabric. This fabric looks like woven fabric but has the qualities of the knit fabric.
Another development doing the rounds in the Japanese Denim Industry is the effort to keep the core of the cotton yarn undyed .. Though this normally happens in the Rope Dyeing method, but the effort is to have much more undyed portion through HAND DYEING which will give very good after washing effects… -
1945 Levi’s from Japan?
It may seem improbable that the most authentic vintage versions of the most famous American Apparel brand – Levi’s – have to be bought in a some ‘Hinoya Plus Mart’ in Japan…
But it is true as New Times Reports . The vintage Levi’s with the most authentic accessories including Scovill Zippers , can be found in this obscure mart in Tokyo.
So much so that Levi’s has been forced to sue them . And of course that has not been without a sense of guilt since Levi’s itself has not been able to produce such authentic versions of their own Brand!Well, we can all trust Japanese to go to any levels to achieve perfection and beat everyone . The same applies to denims also. It must also be marveled that the Japanese are still able to produce and sell their Denim Fabrics at their prices inspite of the fact that this fabric has been commodotised to a large extent ..Hats off to them..