Abstract: Denim fabric and articles of clothing having a “washed” or heather look/effect are produced in a manner that retains color intensity and substantially avoids the waste of chemicals and/or water inherent in conventional washing processes. A first coarse feeder yarn of cotton and/or other natural fiber by ring or open end spinning, and then is continuously dyed (such as by indigo rope dyeing, slasher dyeing, or sheet dyeing). The dyed yarn is dried and then cut up into lengths of about four inches long or less (and opened if necessary) into individual fibers. The fibers are blended with other fibers (e.g. about 10-90% greige fibers) to produce a blended composite. The blended composite is then carded, spun into yarn, and woven into denim fabric having a washed look, or a heather effect, which then can be made into any suitable article. A second coarse yarn made similar to the first coarse yarn may be added to the blending station.

Abstract: Denim fabric and articles of clothing having a “washed” or heather look/effect are produced in a manner that retains color intensity and substantially avoids the waste of chemicals and/or water inherent in conventional washing processes. A first coarse feeder yarn of cotton and/or other natural fiber by ring or open end spinning, and then is continuously dyed (such as by indigo rope dyeing, slasher dyeing, or sheet dyeing). The dyed yarn is dried and then cut up into lengths of about four inches long or less (and opened if necessary) into individual fibers. The fibers are blended with other fibers (e.g. about 10-90% greige fibers) to produce a blended composite. The blended composite is then carded, spun into yarn, and woven into denim fabric having a washed look, or a heather effect, which then can be made into any suitable article. A second coarse yarn made similar to the first coarse yarn may be added to the blending station.

Abstract: A colored yarn is made in an inexpensive manner that allows a wide variety of different colors or hues within the product line, and also allows a wide variety of different effects to be produced including yarns with minimal leather effect, or yarns with a distinct and desired heather effect. A first coarse feeder yarn, e.g. a 1/1 semi worsted yarn, is ring or open end spun with about 2.5 turns per inch. The coarse feeder yarn is dyed, dried, and then cut and opened up into individual fibers about four inches long or less (preferably two inches long or less). The individual fibers are blended with differently colored or hued fibers produced in the same way, and/or with greige or colored staple fibers, to produce a blended composite of fibers. The blended composite is then spun, for example ring spun or open end spun, into a final colored yarn. Rayon fibers may especially effectively and uniquely be utilized, although almost any fiber or mix of fibers can be used.