When we think of textile waste, images of overflowing landfills often come to mind. But textile waste actually begins long before clothing reaches consumers. Across the textile supply chain—from raw material sourcing to production and distribution—significant waste is generated at every stage. By understanding where this waste happens, we can better address the root of the problem and move closer to a circular, waste-free fashion industry.
1. Raw Material Extraction and Fiber Production
The journey of textile waste begins with raw materials, where the extraction and processing of fibers create large amounts of waste:
Cotton: Cotton farming is resource-intensive, often leading to water waste, soil degradation, and pesticide pollution. The leftover plant material after cotton is harvested is typically discarded as waste.
Synthetic Fibers: Polyester and nylon production is energy-intensive and relies on fossil fuels, producing greenhouse gases. During the manufacturing of these fibers, offcuts and damaged fibers are also discarded as waste.
2. Fabric Production and Dyeing
Once fibers are produced, they are spun into yarn and woven or knitted into fabric. This stage introduces additional waste in the form of fabric scraps and chemical by-products:
Fabric Scraps: Around 10-30% of fabric is wasted during cutting and sewing. In large-scale production, this waste adds up quickly, with scraps either disposed of or, in some cases, recycled.
Dye and Chemical Waste: Dyeing and finishing processes contribute up to 20% of global water pollution. Toxic dyes and chemicals are often discharged into water systems, harming aquatic life and contaminating local water sources.
3. Garment Manufacturing and Cutting Room Waste
In the garment manufacturing phase, textiles are cut and assembled into final products. Here, fabric waste accumulates due to offcuts, errors, and overproduction:
Cutting Room Floor Waste: Up to 15% of fabric can end up as scrap during the cutting process. While some manufacturers reuse or sell this scrap, much of it still goes to waste.
Overproduction: To meet demand quickly, manufacturers often produce more garments than necessary. Unsold stock, known as deadstock, frequently ends up in landfills or incinerators.
4. Retail Waste: Unsold Stock and Returns
Waste isn’t only created during manufacturing; retailers also contribute to the problem through unsold inventory and returns:
Deadstock: Fast fashion’s rapid turnover and ever-changing trends lead to unsold items. Deadstock, or unsold stock, is often discarded or destroyed to make room for new inventory.
Customer Returns: Many returns aren’t resold due to minor damages or logistical challenges, adding to the textile waste problem. Some returned items are even destroyed due to the costs associated with restocking.
5. Post-Consumer Waste: Discarded Clothing
While post-consumer waste occurs after a garment’s lifecycle, it is a critical part of the textile waste supply chain:
Shortened Lifespan: With trends changing quickly, clothing is often worn for a shorter time before being discarded. This results in massive amounts of textile waste in landfills worldwide.
Limited Recycling: Only 15% of post-consumer textile waste is recycled, largely due to the challenges of separating and repurposing blended fabrics. Most discarded clothing is either landfilled or incinerated, adding to environmental harm.
6. Steps Toward a More Sustainable Supply Chain
To address textile waste throughout the supply chain, both industry and consumers can play a role:
Innovative Recycling Technologies: Emerging recycling methods, such as fiber-to-fiber recycling, help convert textile waste back into raw materials for new garments.
Deadstock Repurposing Programs: Brands can resell or donate unsold stock rather than discarding it. Some companies are also collaborating with resale platforms to give deadstock a second life.
Circular Design and Production: Designers and manufacturers can minimize waste by using modular designs, zero-waste cutting techniques, and sustainable materials that are easier to recycle.
Textile waste is generated at every stage of the supply chain, from fiber production to the retail floor. Understanding where this waste occurs is the first step toward a more sustainable fashion industry. By rethinking production practices, adopting circular solutions, and supporting brands that prioritize waste reduction, we can all play a role in reducing textile waste and moving closer to a truly circular fashion economy.
If you are a direct-to-customer business looking forward to positively impacting the world with your brand, then get in touch with us at contact@janahcycle.com . Together, we can explore how you can make a positive impact and benefit both the environment and your bottom line.
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