Process & Technology
AGI Denim employs state-of-the-art technology in vertically integrated processes, including spinning, fabric production and garment manufacturing.
Garment
LEED platinum and gold certified units
130 sewing lines
44 robotic arms used for spray process
44 state-of-the-art high-speed laser machines
42 low liquor- ratio washing machines
In-house printing and embroidery facilities
International quality standards
111 washers
Cutting
The denim fabric is cut into individual pieces based on the patterns. Precision is crucial during this stage to ensure that the pieces fit together accurately during the sewing process.
Sewing
This stage involves various processes that bring together the different components of a garment. AGI Denim has invested in numerous automation to increase efficiencies and reduce the inaccuracies involved in sewing.
Washing
Is at the heart of the garmenting process. AGI Denim has built up an arsenal of the latest wet and dry machines to bring the latest washing innovations to market.
Finishing
Our finishing is integral to our quality and inspection process as it is out final step to complete the garment before shipping to the customer.
Environmentally sustainable practices and innovation
Fabric
Ball Warping
Multiple yarn packages are combined into a large ball or warp sheet. This helps ensure an even distribution of yarn during the subsequent weaving process.
Rope Dyeing
Rope dyeing is a specific method of dyeing denim yarn that imparts unique characteristics to the final denim fabric. This technique is widely used in the denim industry, especially for creating the classic deep blue color associated with denim jeans.
Sizing
Sizing is an intermediate protective process which is done to prepare the yarn for the weaving process.
Weaving
The woven process involves interlacing the warp and weft yarns on a loom to create the denim fabric. Different weaving patterns, with the twill weave being the most common for denim, can be used to achieve specific textures and patterns.
Finishing
The unfinished denim fabric undergoes various finishing processes to achieve the desired characteristics. Finishing processes may include washing, softening, or treatments to create distressed or vintage looks.
Spinning
AGI Denim is proud to add the first LEED-certified spinning unit in the country, designed according to Industry 4.0 principles. Our state-of-the-art new LEED-certified spinning has the capacity to produce 48 million pounds of yarn annually. In addition, keeping with our zero- waste focus, we also have the technology to recycle spinning waste into making yarn.
48 million pounds of yarn capacity annually
40% of our energy needs met through renewable energy
State-of-the-art technology with advanced robotics
5 blowroom lines for maximum flexibility
Capable of running several different fibers simultaneously
Booster spindle monitoring system brings us closer to our goal of zero defects
Blending
Fibers from different sources or with different properties may be blended together before the carding process. This ensures a more homogeneous mix of fibers in the subsequent spinning stages.
Carding
The selected cotton fibers are initially carded to remove impurities, align the fibers, and create a continuous web. Carding ensures a more consistent and clean starting material.
Combing
In some cases, the drawn fibers may undergo a combing process to remove shorter fibers and create a smoother, higher-quality yarn.
Roving
The drawn and, if applicable, combed fibers are then twisted and elongated to form a roving. The roving is a slightly twisted strand of fibers that serves as the precursor to the denim yarn.
Ring Spinning
The roving is further twisted and drafted using a ring spinning frame. Ring spinning is a common methoin denim production, as it allows for the production of high-quality, strong yarn.
Winding
The spun denim yarn is wound onto bobbins or cones for storage and transportation. Winding ensures that the yarn is well-organized and ready for the subsequent weaving process.