Denim designers are really changing the way jeans are made. They’re thinking about every step, from the fabric to the final finish, to make denim more eco-friendly.
The reason being that both the EU and US markets have raised the bar when it comes to sourcing denim from Bangladesh. It’s not just about getting the best prices or mass production anymore. There’s a strong shift towards sustainable manufacturing practices which have become essential for most global retailers. This reflects the increasing demand for eco-friendly practices across industries.
Transparency and traceability are now key to maintaining consumer trust, especially with the rise of ESG (Environmental, Social, and Governance) reporting. More and more companies are focusing on this to meet the expectations of conscious consumers. Ethical production is also a non-negotiable factor. Safe working conditions, fair wages and factory certifications like BSCI, SEDEX and WRAP are required to meet the global standards for responsible manufacturing.
The old way of making jeans could use up to 10,000 litres of water just for one pair, most of that during dyeing and finishing.
Therefore, instead of sandblasting or stone washing, which use a lot of water, companies are using lasers to create those worn looks. There’s also ozone and e-flow which clean and fade the denim using gas or tiny bubbles instead of water. And when it comes to dyeing, some are skipping the large vats of water altogether by using waterless dyeing systems like foam dyeing and air dyeing.
Brands like Levi’s Water<Less, Jeanologia and Candiani are showing that you don’t have to waste tonnes of water to make great-looking jeans.
But it’s not just about water anymore. There’s also a big push to reduce the chemicals we use. Traditional denim production relies on harsh stuff such as heavy metals, synthetic indigo, strong bleaches. These aren’t just bad for the environment, they’re harmful to workers and even to people who wear the clothes. To address this, designers are turning to sustainable alternatives such as natural and bio-based indigo derived from plants or biosynthetic sources, green chemistry with biodegradable and non-toxic inputs (like GOTS-approved or ZDHC-compliant chemicals) and enzyme washing which uses natural enzymes to create faded effects without the use of bleach. These cleaner chemical inputs still allow for the creation of vintage fades and textured effects, but without the toxic legacy.
| “Instead of sandblasting or stone washing, which use a lot of water, companies are using lasers to create those worn looks. There’s also ozone and e-flow which clean and fade the denim using gas or tiny bubbles instead of water. |
This shift includes using mono-materials like 100 per cent cotton or recyclable blends that make it easier to recover and reuse fabric. Blends like Tencel™ add strength and break down naturally, while newer options like Coreva™ (made from natural rubber) and Roica V550 (a recyclable, bio-based stretch) offer eco-friendlier ways to add stretch. Designers are also moving toward minimal trims, replacing metal rivets with embroidered bartacks and exploring design features that extend a garment’s life such as zip-off panels, adjustable fits and reversible styles. Designers are even incorporating take-back or resale-ready features such as QR codes or tags linking to care, resale or recycling instructions.
Durability is another key focus. Features like 3×1 twill weaves, reinforced seams in high-stress areas, timeless shapes and repair-friendly touches such as modular construction or mending panels are helping denim last longer. By thinking through all these details from the start, especially when working with special weaves and eco-blends, denim is becoming more sustainable and more enduring.
| COLOUR AND WASH TRENDS
1. NATURAL DYES: ECO-COLOUR, EARTH-FIRST AESTHETIC Denim brands are turning to plant-based, mineral and food-derived dyes like indigofera, turmeric, madder root and even onion skins as alternatives to synthetic chemical dyes. Features Sustainable and non-toxic: Natural dyes reduce water pollution and are gentler on skin and the environment. Artisanal feel: Irregular, earthy tones give the feel of being one-of-its-kind and hand-crafted. Appeal to eco-conscious consumers: These dyes reinforce a transparent, slower fashion model. Trending looks Sandy taupe’s, sage greens, clay reds, indigo-indigo and muted pastels are all derived from natural pigments. 2. VINTAGE FINISHES: NOSTALGIA WITH A MODERN EDGE Vintage denim is being reimagined with finish techniques that replicate natural aging and wear—without waiting 10 years or buying second-hand. Key effects Whiskering: Faded lines at stress points (hips, thighs) that mimic authentic aging. Stonewash: A softened look and feel using enzyme alternatives (instead of real pumice stones). Tints and over-dyes: Subtle overtones of yellow, grey or brown give jeans that pre-worn patina. Features Nostalgia-driven: Y2K and ’90s aesthetics are driving interest in washed, broken-in looks. Adds character: Consumers love denim that looks lived-in and personalised. Pairs with looser silhouettes: Enhances the ‘vintage revival’ happening with wide-leg and relaxed fits. Trending washes Sun-faded blues, dirty indigo, overdyed blacks, yellowed seams, soft grey tints. 3. LASER TECHNIQUES: HIGH-TECH MEETS LOW IMPACT Laser tech is replacing traditional, resource-heavy methods like sandblasting and hand-scraping. How it works Lasers ‘burn’ the desired fade or pattern into the denim surface. They can be paired with ozone washing or e-flow to reduce water, chemicals and labour. Features Waterless and clean: They significantly reduce water and chemical use. Highly precise: The tech allows for detailed customisation — from distressed patterns to custom prints. Worker-safe: The tech eliminates harmful exposure to chemicals and dust for factory workers. Creative directions with laser Text-based graphics, faux distressing, ‘tattooed’ patterns, barcode effects, fade gradients. |
Kamrun is a dynamic expert in denim development, with a strong track record of year-over-year growth in product innovation. With 15 years of extensive experience, Kamrun has deep knowledge of garment fit, fabric and wash development—guiding products from concept to production.
