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How We Make Our Jeans: The Sewing

We continue our three-part series about how our jeans are made. Chapter two investigates the highly coordinated process that is required to stitch our jeans together.

Jeans Intelligence | 13.02.2015

Making a pair of JACK & JONES jeans is no simple feat. As chapter one of this series explored, turning fuzzy white cotton into a sturdy blue fabric is a complicated procedure. But, while weaving denim is an almost completely automated process, the stitching step is where craftsmanship really starts to matter.

Stitching a pair of jeans involves a lot of teamwork; it requires many hands, eyes, and creative minds working together. The jeans pass through various stitching stations and the job carried out at each station is equally crucial for the final result; a handcrafted pair of JACK & JONES jeans that meet our first-rate standards.

Pattern for JACK & JONES How the pattern for JACK & JONES jeans is made
How we cut the pattern for JACK & JONES jeans

The Stitching Process Starts On a Computer

Okay, didn’t you just say that stitching is a manual process? That’s right, but before the seamstresses can start churning out awesome jeans, they need to know which pieces go together.

That’s where the pattern maker enters the stage. Not only will the pattern help seamstresses distinguish the fronts from the backs, it also determines the fit of the jeans.

Once a pattern is developed and approved by our Jeans Intelligence Studio, it will be printed on paper and placed on as many as sixty layers of fabric. Then, the pattern cutter uses a jigsaw-like cutting machine to cut out all the pieces. There is absolutely no room for errors – a wrong turn with the saw can’t be undone.

How-we-sew-JACK-&-JONES-jeans-1---538x314_web How we sew JACK & JONES jeans
How we sew JACK & JONES jeans

15 Minutes of Needle Work

Once the denim is cut into pieces of legs, pockets, waistbands and so on, the sewing can begin. A generic pair of five-pocket jeans consists of around 20 individual pieces of fabric and it takes around 15 minutes to sew them together. If the jeans have special design features such as extra pockets, there will be more pieces and the sewing will take a little longer.

Most of the stitching is done manually on sewing machines in assembly lines. Despite being optimised by technology, the stitching process is rooted in dexterity; it requires great hand and eye coordination, but you better believe that our seamstresses know what they are doing – and that they’re fast at it!

When the jeans are stitched, they go through thorough controls to make sure that they meet our quality standards. The stitched raw jeans are packed according to style and are sent off to the laundries to be washed and treated.

Facts about the sewing process:

– On average, 1.35 metres of wide loom fabric are used for one pair of jeans.

– 240 metres of thread are used for a pair of five-pocket jeans.

– While it takes 15 minutes to stitch a pair of five-pocket jeans, the average time needed for a pair of jeans to go from the cutting stage to its final washed look is 1.5 hours.

In the third and final instalment of our “how we make our jeans” series, we explore the washing and treatment process, which is where the denim really comes to life.

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