The Life of a Doon Garment: From Soil to Shoulder

    1.

    Step 1: The Harvest

    We use three main plants; each harvested for a specific feel.

    • Cotton & Khadi: The fluffy white bolls that grow around the cotton seed are harvested. It’s the gold standard for a reason. Soft, breathable, and familiar.
    • Flax (Linen): The stalks of the flax plant are pulled rather than cut, then soaked and beaten (a process called retting) to reach the long, woody fibres inside that give linen its crisp, earthy texture.
    • Hemp: The stalks are cut and the “bast” fibres from the inner bark of the stalk are separated. These fibres give hemp its immense strength that, extraordinarily, softens up beautifully over time.

    Step 2: The Yarn

    This is where the character of the fabric is determined.

    • The Old Way (Khadi & Linen): Fibres are hand-spun on a wheel (charkha). This creates that breathable, irregular texture.
    • The Modern Way (Cotton & Hemp): Fibres are machine-spun for a consistent, smooth finish.
    • The Epic Way (Ikat): The yarns are bundled and resist-dyed before they ever touch a loom to create that quintessential hazy ikat pattern.

    Step 3: The Loom

    The yarns are now ready to be turned into “greige” (raw) fabric.

    • Hand-Loomed: Khadi, Linen, and Ikat are woven by hand. A slower process that preserves the tension and “air” in the weave. As the Ikat fabric has already been dyed, head straight to Step 5.
    • Power-Loomed: Our Hemp and Standard Cotton are woven on mechanical looms for a tighter structure.

    Step 4: The Colour

    If the fabric wasn’t pre-dyed (like Ikat), it heads to the print tables or the dye vats.

    • Block Printing: The fabric is pinned to long tables and stamped by hand with a series of hand-carved wooden blocks. Poetry in motion.
    • Screen Printing: The fabric is laid out on long tables, and a series of large screens are used to pull ink across the surface, creating crisp, bold patterns.
    • Digital Printing: Modern precision where inkjet tech applies complex designs directly to the fibre.
    • Vat Dyeing (Future): The fabric is submerged in deep vats for a rich, solid “through-and-through” colour.

    Step 5: The Final Cut

    The finished yardage is sent to our workshop.

    • Pattern Cutting: Maximising the fabric to ensure minimal waste whilst maintaining the perfect cut. The job of a master tailor.
    • Stitching: Precisely assembling a Doon silhouette with reinforced seams.
    • Final Wash: Softening the fibres so they’re ready to wear the moment they arrive.

    The Finish Line: Your Wardrobe

    The final step is the longest one: you wearing them. These fabrics are meant to be lived in, washed, and worn until they feel like a second skin.