Denim Fabric Including Recycled Material

A process to make the denim fabric comprising the steps of:

• a) preparing a mixture of recycled cotton and other cotton into a warp yarn;
• b) mixing the warp yarn with dyes and chemicals;
• c) preparing a mixture of recycled polyester and spandex into a filling yarn;
• and
• d) preparing the denim yarn from the warp yarn of (b) and the filling yarn of (c).

A denim garment produced from denim fabric, the denim fabric comprising:

• a) from about 25 wt % to about 40 wt % based on the denim fabric of post-consumer recycled polyester,
• b) from about 25 wt % to about 40 wt % based on the denim fabric of recycled cotton,
• c) from about 25 wt % to about 40 wt % based on the denim fabric of other cotton, and
• d) up to about 3% based on the denim fabric of spandex.

A process for dyeing warp yarn of a denim fabric comprising the steps of:

• a) dyeing the warp yarn with minimum overflow as compared to traditional denim dyeing methods;
• b) introducing said warp yarn to an aqueous solution comprising sulfur dye;
• c) recovering the aqueous solution bath comprising sulfur dye in the form of recovered sulfur dye bath;
• and
• d) re-using the recovered sulfur dye bath in dyeing of other fabrics.