How Denim Is Made: Blending Synthetic Fibers With Denim

Blending Synthetic Fibers With Denim

Welcome to our series of articles on the denim manufacturing process. In a series of posts, we will cover all the processes involved in denim fabric production including cleaning cotton fibers, blending, spinning, warping, dyeing, beaming, sizing, weaving, finishing, and packaging. From cotton fiber to the final product you can buy at ZEVA DENIM.

Denim fabric, which has been popular for more than a century as a fashion clothing fabric. The fabric’s durability, versatility, and unique visual appeal have made it a consumer favorite. The popularity of denim has led many denim producers to experiment with different technologies and fibers to improve their properties.

One of the links in the production of denim fabrics is the blending of synthetic fibers. Blending synthetic fibers with denim has many benefits, including increased durability, improved color retention, reduced shrinkage and wrinkling, and enhanced stretch and comfort.

In this article, we’ll explore the process of blending synthetic fibers with denim, the types and benefits of synthetic fibers used, and specific practical examples of them.


What Is Mixing/Blending?


Blending is the process of mixing different fibers (natural or synthetic) to produce fabrics with specific properties. As we all know, cotton is the main fiber used to make denim. So blending is mixing cotton with synthetic fibers such as polyester, spandex, modal, tencel, and acrylic. Depending on the desired properties of the denim fabric, the blending process can be done at high or low ratios.

Blending synthetic fibers with denim has many advantages over using 100% cotton. For example, it increases the durability and strength of fabrics, thus extending their lifespan. It also provides enhanced stretch and comfort, making denim more flexible for different body shapes and movements.


How to Blend in Denim Manufacturing?


The first stage in denim fabric production is blending. Blending refers to the process of Combining various grades or different types of fiber to yield the desired properties. In denim production, the blend combines cotton and synthetic fibers such as polyester, rayon, or spandex.

The main purpose of the blend is to produce a material that is both comfortable and durable. Cotton is an excellent fiber for producing comfortable clothing due to its natural softness, while synthetic fibers provide durability and stretchiness. Synthetic fibers are often used in denim fabric production to improve the fabric’s strength, and resistance to fading, and to add stretch and flexibility.

The blending process begins with selecting a suitable combination of fibers. The chosen fibers are then opened using a picker machine or other equipment to break up the fibers and fluff them up. The fibers are then fed into a carding machine, which separates and aligns the fibers to create a uniform web.

Next, the web is fed into a drawing frame, where the fibers are stretched and twisted to create a more consistent strand. The consistency of the strands ensures that the resulting fabric is even and free from defects.

The final stage of the blending process involves using a roving machine to spin the strands of fiber into a yarn. The yarn is then put on a cone and sent to the spinning process.


What Are the Advantages of Blending Synthetic Fibers With Denim?


  • Increased durability and strength

Denim fabrics that are blended with synthetic fibers are more durable and resistant to tearing and fraying. Synthetic fibers have higher strength and abrasion resistance than cotton, making them ideal for reinforcing denim. Blending denim with synthetic fibers also reduces the risk of tearing and fraying, keeping the fabric intact for longer.

  • Reduce shrinkage and wrinkling

Blending synthetic fibers with denim reduces shrinkage and wrinkling, two common problems with 100% cotton fabrics. Synthetic fibers such as polyester have dimensional stability that prevents the fabric from shrinking or stretching. They also minimize wrinkling, making denim easier to wear and wash every day.

  • Improved color retention and fade resistance

Denim blended with synthetic fibers has better color retention and fade resistance than 100% cotton denim. Synthetic fibers resist color bleeding and fading, making denim durable and looking vibrant and bright. This is especially beneficial with dark wash denim, as dark washes fade faster than lighter denim.

  • Enhanced stretch and comfort

Blending synthetic fibers such as elastane/spandex with denim enhances stretch, making the fabric more comfortable and flexible. Spandex fibers can expand up to five times their original size, providing freedom of movement and preventing shrinkage. This is especially beneficial for making skinny and slim-fit jeans, as they need to stretch to fit snugly against the body.

  • Cost-effective alternatives to natural fibers

Blending synthetic fibers with denim allows producers to reduce costs by using less cotton. Synthetic fibers are cheaper than natural fibers, making them an economical alternative for denim production. By blending cotton with synthetic fibers, denim manufacturers can create affordable, durable fabrics that offer better performance.


What Are the Popular Synthetic Fibers for Blended Denim?


  • Polyester

Polyester is the most common synthetic fiber used for blending with denim. It’s affordable, durable, and has excellent abrasion and tear resistance. Polyester also has excellent color retention, making it ideal for producing dark-wash denim fabrics. The denim fabric blended with polyester fibers is soft and smooth for comfort.

  • Spandex/Rayon

Spandex or elastane is a synthetic fiber with excellent stretch and recovery properties. Fabrics blended with elastane can stretch up to 500% of their original size and return to their original shape. Denim fabrics blended with elastane provide increased comfort and fit, especially with slim fit and skinny jeans.

  • Modality

Modal is a synthetic fiber made from beech wood pulp. It is a soft and breathable fiber with excellent moisture-wicking properties. Lightweight and comfortable, Modal fiber is ideal for blending with denim to produce a lightweight and breathable fabric.

  • Tencel/Lyocell

Tencel or Lyocell is a synthetic fiber made from wood pulp. It has excellent breathability and moisture-wicking properties, making it an ideal fiber for summer wear. Tencel fiber is also environmentally friendly and sustainable, making it a popular choice for environmentally conscious denim producers.

  • Acrylic

Acrylic is a synthetic fiber that offers excellent insulation and warmth. It is often blended with cotton to produce winter denim fabrics. Denim blended with acrylic is soft and warm, perfect for winter.


How the Blending Ratio and Technique of the Fabric Will Affect the Denim?


Blend ratios and techniques vary depending on the desired properties of the denim.

High-ratio blending involves blending large quantities of synthetic fibers with cotton to produce fabrics with specific properties.

For example, high percentages of spandex blends are ideal for super-stretch denim. A blend of 98% cotton and 2% elastane is often used for jeans that require a lot of stretch. The elastane provides increased flexibility, allowing the denim to stretch and recover without losing its shape. This type of denim is commonly used for skinny jeans and other form-fitting styles.

How Denim Is Made
How Denim Is Made


Low-ratio blending involves blending small amounts of synthetic fibers with cotton to enhance certain denim properties. For example, blending 3% modal with 97% cotton enhances the softness and moisture-wicking properties of the fabric. Or Adding just 1% of Tencel to a cotton denim fabric can improve its moisture-wicking properties, making it more comfortable in humid or sweaty conditions.

Blending technologies such as open-end spinning and ring spinning can also affect the properties of denim fabrics. Open-end spinning involves making yarn by feeding fibers into a spinning rotor, while ring spinning involves twisting fibers into yarn using spinning rings. Each spinning technology produces a yarn with different properties, affecting the overall properties of the denim fabric.




Blending synthetic fibers with denim has many advantages including enhanced durability, stretch and comfort, reduced shrinkage, wrinkling, improved color retention, and fade resistance.

The use of synthetic fibers in denim production is a cost-effective alternative to natural fibers without compromising denim’s unique properties and style.

Blending denim with polyester, spandex, modal, lyocell, and acrylic will enhance the quality of the denim, making it more durable, comfortable to wear, and resistant to shrinkage and wrinkles.

By blending with low or high proportions and different spinning techniques, denim producers can obtain denim fabrics with specific properties, ensuring consumer satisfaction and comfort.

After the blending process is complete, the next stage is sinning. so we’ll cover that in the next article, which you can read by clicking How Denim Is Made: Spinning Techniques and Processes.

If you want to continue learning more about denim fabrics, please follow our blog.

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Thanks for reading!



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