01
Classic straight and rigid
12.5–16 oz rigid denim, five pockets, copper shanks, bartacks, flat-felled back rise, and chain-stitched leg openings suit heritage, streetwear, and workwear.
Raw-to-wash denim engineering
Denim & Jeans Manufacturing
Fenalt manages custom denim and jeans production across pattern engineering, indigo fabric, heavy-duty assembly, hardware, laundry, and export.
Launch rigid selvedge, comfort stretch, vintage-washed jeans, or denim outerwear with a 50-piece-per-style MOQ and AQL 2.5 inspection.
Direct answer
One managed denim workflow
Fenalt integrates mills, laundry, hardware, and cut-and-sew units under one production path. We translate the tech pack, adjust the pattern for wash shrinkage, source custom shanks and rivets, coordinate heavy stitching, and approve dry and wet finishing.
The result is a production-ready denim style with wash evidence, standard industry tolerances across waist, rise, thigh, knee, and leg opening, and final inspection under ANSI/ASQ Z1.4 Level II with AQL 2.5.
Silhouette engineering
Denim styles built for fabric behavior
02
Modern tapered and slim
10.5–12.5 oz stretch denim uses a contoured waistband, reinforced TC 65/35 pocketing, and narrow lock-stitched side seams for a clean cuff roll.
03
Loose, wide-leg, and utility
13–15 oz denim supports articulated knees, expandable bellow cargo pockets, heavy snaps, double-layer seats, and three-needle chain stitching.
04
Jackets and overshirts
11–14.5 oz denim supports truckers, chore coats, and overshirts with welt pockets, flap chest pockets, adjusters, and branded tack buttons.
Material selection
Denim weight and composition
| Classification | Composition | Weight | Best suited for |
|---|---|---|---|
| Rigid heavyweight | 100% combed ring-spun cotton | 13.5–16 oz / 457–542 GSM | Raw jeans, heritage jackets, heavy workwear |
| Midweight comfort stretch | 98% cotton / 2% elastane | 10.5–12.5 oz / 356–423 GSM | Slim jeans and daily lifestyle pants |
| Authentic selvedge | 100% cotton shuttle-loom | 12–15 oz / 406–508 GSM | Premium collections and limited drops |
| Lightweight denim / chambray | Cotton or cotton / Tencel | 6–9 oz / 203–305 GSM | Shirts, summer chore pieces, light dresses |
| Eco-performance denim | 70% organic cotton / 28% recycled poly / 2% elastane | 11–13 oz / 373–440 GSM | Technical lifestyle and sustainable streetwear |
Construction and laundry
The denim details that survive the wash
Heavy fabric, high-tensile thread, and calibrated laundry must be specified together.
Seam engineering
Structural seams use 8–10 SPI; topstitch and pocket decoration use 10–12 SPI. Tex 60–80 core-spun polyester or poly-wrapped cotton supports wash tension. Flat-felled seams use feed-off-the-arm double or triple needle chain stitch.
8–12 SPI
Hardware
Copper or zinc-alloy shanks and rivets, 28-stitch bartacks, No. 5 antique brass or nickel auto-lock zippers, and a chain-stitched waistband with bias-cut canvas stiffener support the garment.
SHANKS / RIVETS / YKK
Dry and wet processing
Hand scraping, resin whiskers, pocket-edge grinding, laser distressing, enzyme bio-wash, calibrated stone wash, bio-polish, sulfur or direct tinting, atmospheric ozone, and waterless laser oxidation are coordinated through wash swatches.
WET + DRY LAUNDRY
Production workflow
From shrink calculation to export
- 01
Tech pack and shrink calculation
Warp and weft shrinkage is measured from the wash recipe, commonly 3%–8%, and built into the digital pattern.
- 02
Sampling and wash blanket
Sampling takes 10–15 days plus 3–5 days courier; the PP sample travels with a wash blanket showing color and surface options.
- 03
Bulk cut and sew
Relaxed rolls are CNC cut, then dedicated denim lines assemble the garment before laundry.
- 04
Laundry and final trims
Enzyme, stone, laser, ozone, or approved finishing is followed by hems, leather patches, metal checks, and packing.
- 05
Dispatch
DAP supports small batches and FOB the designated export port supports bulk sea freight.
Managed quality
Denim inspection beyond appearance
AQL
ANSI/ASQ Z1.4 Level II with AQL 2.5.
Dimensions
Standard industry tolerances across POM.
Crocking
Wet and dry tests under AATCC methods; medium-to-dark indigo targets at least Grade 3.0 dry crocking.
Hardware
Rivets and shanks tensile tested; minimum 90 N pull force specified in the draft.
Metal detection
Finished garments pass dual-head detection before polybagging.
Questions and answers
Denim manufacturing FAQs
What is the MOQ?
Fenalt's standard MOQ is 50 pieces per style.
How is wash shrinkage controlled?
Wash blankets run through the intended wet and dry recipe first. Warp and weft shrinkage, often 3% to 8% depending on fabric and recipe, is used to scale the digital pattern before bulk cutting.
Which wash options are available?
Stone, enzyme bio-wash, bleach fading, tinting, ozone washing, laser distressing, hand scraping, and sulfur or direct overdyeing can be developed through approved wash swatches.
What are the lead times?
Sampling is 10–15 days plus 3–5 days shipping. Bulk is 15–20 days from PP sample and wash approval to export dispatch.
Can you develop hardware and leather patches?
Yes. Custom shanks, copper rivets, zipper pulls, jacron or genuine leather waist patches, and branded hardware can be coordinated with vector files during sampling.
How are final shipments handled?
DAP supports small-batch courier delivery; FOB designated port of export supports bulk sea freight.
Start your denim line
Develop the wash before the bulk
Send your block, denim weight, hardware, wash reference, quantity, and destination. Fenalt will build the approval path.