As anyone who works in apparel will tell you, the deck is stacked against things running on auto pilot. Murphy’s Law? Not really. Making clothing involves very ‘touchy’ elements: cotton fiber (which varies as the weather does), yarns, fabrics, dyes, washing processes, sewing needle tension, human judgement, and how those things interact with each other. If the water temperature during the dyeing process is 2 degrees off, fabric shrinkage can go way off course. It’s one of the reasons no one has quite figured out how to teach robots to make clothes. As the president of a major denim factory said in 1970, we’d colonize Mars before figuring out how to automate clothing production.
For the past several days I huddled with our partners in Peru to solve a perplexing issue. While 90% of our organic cotton fabrics this season were great as usual, there were a handful of colors that were, well, too soft. That may sound weird, but these colors felt a bit more like pajamas (soft and fuzzy) instead of how we want our organic women’s tees and dresses to feel (soft and silky smooth).
This had the technicians at our knitting and dyeing mill scratching their heads as they followed the same formula for knitting, dyeing, and washing they always have.
After several days of testing (and the usual jokes about how much easier it would be to make cardboard boxes) we found it. Our dye producer– maker of some of the gentlest dyes on earth – slightly changed their formula on some colors to be even more eco-friendly. While happy they took that initiative, they didn’t inform our dyeing facility. Sure enough, the very slight change interacted with the wash process and created a slight but perceptible change in how the fabric feels.
Once we discovered the issue, the technicians made an adjustment to the wash formula, we did a few more dye and wash tests, and voila! Our fabrics were as smooth as silk again. We gave the all clear for Fall/Winter 2018 production.
Needless to say, this will add a couple weeks to our production calendar, but we should be still ok to have most fall goods in the door by September 1.