Lean manufacturing to minimise textile waste
The textile industry has both a responsibility and an opportunity to lead the charge towards a more sustainable future, says Rajesh Meena.
The textile industry, one of the largest contributors to global waste and pollution, is now pivotal to balancing the demands of sustainability with the pressures of innovation. Contributing to nearly 10 per cent of global greenhouse gas emissions and responsible for about 20 per cent of water pollution worldwide, the industry’s environmental impact is significant and growing. In fact, without immediate intervention, emissions from textile production are projected to account for almost 30 per cent of global emissions by 2030.
As consumers increasingly prioritise sustainable and ethical fashion, manufacturers are under growing pressure to adopt more responsible practices. In response, the textile industry is embracing a leaner approach — one that focuses on waste reduction, operational efficiency, and environmental preservation. This shift not only aims to address the urgent global challenges facing the planet but also opens new doors for manufacturers to innovate and lead in sustainability.
Let’s explore the practical steps manufacturers can take to reduce their environmental footprint and make a lasting impact on the future of fashion.
Transitioning to sustainable materials
One of the most critical steps in reducing textile waste is transitioning to sustainable materials. Traditional fibres such as cotton and polyester often come with significant environmental costs, from the heavy water use in cotton cultivation to the emissions generated in synthetic fibre production. To address these impacts, manufacturers are increasingly adopting alternative fibres derived from renewable and recycled sources.
For example, Spinnova, a Finnish company, has developed a groundbreaking method to convert wood pulp and textile waste into biodegradable fibre. Remarkably, this process eliminates harmful chemicals and reduces water consumption by 99 per cent, while cutting carbon emissions by 74 per cent compared to conventional cotton production. Other innovators, such as Tencel and Recover, are producing fibres from sustainable forestry practices and recycled textiles, respectively, creating a closed-loop system that minimises waste at every stage of production.
The momentum for change is clear, a 2023 report from Textile Exchange found that the global use of recycled fibres has surged as more manufacturers commit to sustainable practices. This transformation not only mitigates environmental impact but also empowers the industry to meet consumer demands for eco-conscious fashion in a meaningful way.
Embracing advanced manufacturing to cut down on textile waste
Advanced manufacturing techniques have become the cornerstone of efforts to curb textile waste, with manufacturers leveraging automation, robotics, and precision machinery to streamline production and reduce material overuse. For example, advanced weaving and knitting technologies have enabled companies to produce high-quality fabrics with minimal offcuts, resulting in less waste at the production stage.
Digital fabric printing is another transformative innovation making strides in sustainability. Unlike traditional dyeing methods that consume large amounts of water and generate chemical waste, digital printing requires significantly less water and energy while still delivering vibrant, detailed designs. According to the report, integrating digital solutions into textile manufacturing can reduce production waste by up to 50 per cent while shortening lead times, supporting both economic and environmental goals.
Adopting a circular economy to combat textile waste
The circular economy model is gaining traction as a viable solution to textile waste crisis. This approach emphasises reusing and recycling resources to extend the life cycle of products, significantly cutting down on landfill contributions and promoting sustainable fashion. With innovations in textile recycling technology, both post-industrial and post-consumer waste can now be broken down and reintegrated into the production chain.
Industry giants like H&M Group are investing heavily in textile-to-textile recycling facilities, aiming to achieve a fully circular production process. According to McKinsey’s 2020 report, for the fashion industry to align with the 1.5°C global warming limit set by the Paris Agreement, it must reduce emissions by half by 2030, reaching 1.1 billion metric tonne of CO₂-equivalent emissions. Without these reductions, the industry could contribute up to 2.7 billion metric tons of emissions by 2030.
Despite continuous research and advancements, the textile recycling infrastructure still faces challenges such as sorting complexity and contamination. Collaborative efforts among governments, industry leaders, and environmental organisations are essential in building a robust recycling infrastructure and creating policies that encourage sustainable practices at every stage of the textile lifecycle.
Zero waste design to minimise textile waste from the start
Reducing textile waste begins right at the design stage, where zero-waste techniques are making a significant impact. By carefully planning pattern layouts and optimising fabric use, designers can ensure that nearly every piece of material is utilised, greatly cutting down on waste and diverting fabric from landfills. This design approach, gaining popularity across both established brands and independent designers, represents a shift toward mindful resource use in fashion.
The Council of Fashion Designers of America (CFDA) reports that zero-waste design methods can reduce fabric waste by up to 85 per cent, underscoring its potential to transform manufacturing practices. As the industry moves toward more sustainable practices, adopting these techniques can drive meaningful reductions in environmental impact while highlighting the role of design innovation in sustainability.
Shift toward conscious consumerism in fashion
The rise of conscious consumerism is driving change within the textile sector, as more shoppers demand transparency and accountability from brands. To stay relevant, manufacturers are increasingly sharing information on their environmental impact and actively participating in sustainability initiatives, building trust with eco-aware customers. Educating consumers on sustainable actions, like recycling, repairing, and reselling garments, further supports efforts to reduce waste and promotes mindful consumption.
Brands like Patagonia and Levi’s have led the way with take-back and repair programs, helping customers extend the life of their clothing and lessen the demand for new production. This shift not only aligns with the values of today’s shoppers but also fosters shared responsibility for sustainability across the fashion lifecycle. As consumer awareness grows, brands are urged to respond in kind, making sustainable choices an industry standard rather than an exception.
Paving the path to a sustainable future in textiles
The textile industry has both a responsibility and an opportunity to lead the charge towards a more sustainable future. Building a truly sustainable textile ecosystem requires a unified effort among manufacturers, policymakers, and environmental organisations. By incorporating sustainable materials, utilising advanced manufacturing practices, embracing recycling and circular economy models, and fostering collaboration across sectors, manufacturers can make substantial strides in reducing textile waste. This approach not only benefits the environment but also enhances efficiency and resonates with the values of today’s conscious consumers. As the industry evolves, a commitment to innovation, transparency, and partnership will be essential to create a future where fashion and sustainability thrive together.
About the author:
Rajesh Meena is a seasoned leader with over 18 years of expertise in business development, supply chain operations, and service management across the e-commerce, retail, and transportation sectors. As a Founding Member (Infra & Ops) at ZYOD, Rajesh is instrumental in revolutionising the fashion industry through sustainable, end-to-end design-to-delivery solutions. An OKR-certified professional, Rajesh specialises in strategy formulation, team leadership, P&L management, and process optimization. He has previously held senior leadership positions at organisations such as Fashinza, BlackBuck, and Ola, where he spearheaded innovative supply chain strategies and drove significant business growth.
