Carbon Footprint: A Strategy by Textile Industry

The global textile and  apparel industry continues to have a strong impact on climate change. Recent industry data shows that fashion and textile activities produced close to 944 million tonnes of carbon dioxide equivalent in 2023, which was higher than the previous year. Emissions increased by about 7.5% as  clothing production expanded and the use of virgin polyester remained high, accounting for more than half of all fiber consumption. If this trend continues, total emissions from the industry could rise to around 1.24 billion tonnes by 2030. This would mean nearly a 50 % increase compared with current levels, creating serious pressure on global climate targets. Textile manufacturing is still more carbon-intensive than many transport industries, with raw material production and early processing stages responsible for the largest share of emissions.

Carbon Footprint in Industries Today

A large percentage of emissions in textiles is generated during the initial phases of the supply chain. Approximately 70-85% of the overall emissions are associated with the extraction of the raw material, fiber processing and wet processing operations, including dyeing and finishing. The polyester manufacturing process alone contributes hundreds of millions of tonnes of greenhouse gases every year. Before the manufacturers execute the plans to reduce them, we need to understand the locations of the largest footprints.

Select Raw Materials with Low Carbon

The choice of the material has a huge impact on carbon production. Now, the most consumed fiber is polyester, comprising approximately 54% of fiber fabrication, but only approximately 14.8 % of polyester is either recycled .

The use of synthetic materials necessitates high emissions through virginity. Recycled polyester, organic  cotton, and regenerative fibers can also reduce emissions considerably by switching. Regenerative agriculture can enhance the carbon storage of the soil, and organic cotton needs fewer inputs of chemicals.

Brands Action

Brand actions clearly show how material choices can help reduce carbon emissions. But in this era of advertisement , we should not be traped in Green Washing . Greenwashing is a deceptive marketing practice where companies mislead consumers into believing their products, services, or operations are more environmentally friendly or sustainable than they actually are, often through vague claims, misleading labels, nature imagery, or focusing on minor eco-friendly aspects while hiding significant negative impacts.

Apparel manufacturing techniques

Most of International brands has increased its use of recycled polyester, reaching around 94%, while continuing its goal to shift more of its total materials toward sustainable sources.

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Nike is focusing on lowering material emissions by increasing recycled content and improving product design efficiency, alongside its plan to use clean energy across operations.

Inditex, the parent company of Zara, has committed to using only recycled or sustainably sourced fibers by 2025, covering cotton, polyester, and other key materials. Several global retailers are also working with textile recycling companies to secure long-term supplies of recycled fibers for the coming years.

These actions show that strong materials policies can play a major role in lowering emissions and improving sustainability performance across the textile and apparel industry.

Improve Energy Efficiency

To minimize emissions, manufacturers can update their modern machines that are energy efficient and optimize processes. The energy monitoring systems installed in real time assist in determining the areas where electricity and heat consumption can be reduced.

In the case of steam processes, heat recovery systems use steam by-products and thus reduce fuel consumption and emissions.

The work of some factories that use extensive energy efficiency audits records the saving of 20 to 30% of energy in several years. The operating cost is reduced as well, enhancing the long-term competitiveness.

Switch to Renewable Energy

Use of renewable energy instead of fossil fuel energy in the factories will drastically lower the factory emission drastically.

Most textile manufacturers in Asia and Europe are placing solar roof tops or buying renewable energy credits. In Vietnam, as an example, the major apparel firms agreed to buy the renewable electricity directly from manufacturing premises. This reduces carbon emissions, and it reduces the risk of being exposed to energy price volatility.

Global fashion companies are also recording advancements in renewable energy in supply chains as part of sustainability undertakings.

Implement purer processing methods.

Wet processing, which includes dyeing and finishing, is one of the most carbon-intensive stages in the production of textiles.

Advantages of Updated Technologies

Low liquor ratio dyeing entails a saving on water and energy.

Waterless dyeing systems that use less water by using large amounts of hot water are used. Digital printing uses less waste, chemicals, and energy.

Depending on the technologies applied at the factories, it is possible to reduce energy consumption by 30% or even more in critical processing areas. These technologies also reduce the cost of wastewater treatment and support environmental regulations.

Reduce Waste and Overproduction

Textile waste is enormous. Approximately 92 million tonnes of textile products find their way to landfills annually, with just a small percentage of these being recycled. One of its significant sources of waste and additional emissions is overproduction.

Manufacturers can embrace improved forecasting of demand and inventory planning to manufacture closer to the actual needs of the market. Better pattern layout and cutting technology can decrease the waste of  fabrics by 15 to 25%. Caliber waste management mechanisms also trap the scraps that can be recycled and used back into the production.

Cooperate on Circular Economies

When used on a large scale, circular economy solutions can reduce carbon emissions in the textile industry by a rate of 44%all around the world. This involves creating products that last long and are repairable, can be used again, and enhance recycling systems.

Such programs, like take-back schemes, make  garments last longer, and unnecessary new raw materials are not used. The lifetime of the garments also decreases their carbon footprint by extending their life. Customers are becoming more interested in the brands and new suppliers that do not only promote product stewardship and material recirculation.

Record Emissions Information

The major industry coalitions now assist manufacturers in benchmarking their emissions and establishing science-based targets. Reporting structures allow the brands and suppliers to benchmark and focus on areas to invest in. By 2025, most companies will be reporting sustainability and climate numbers, indicating an increased focus on accountability.

This information assists manufacturers in gaining insight into the areas with the maximum emissions and monitoring improvements. Formal targets also increase the desirability of manufacturers as collaborators with international brands that strive to achieve low-carbon supply chains.

Make Sustainability a Strategic Priority

Consumers and retailers are shifting to environmentally friendly products. Studies indicate that a large number of consumers would be ready to pay an increment of 20 to 30% of sustainably made clothing. This forms a business motivation for the textile producers who are able to prove lower carbon footprints and open practices.

Make a list of Activity can be

• Avoid

• Reduce

• Replace

• Offset

Manufacturers who incorporate an idea of reducing carbon into their venture are more adaptable to regulatory shifts and market demand fluctuations. Early intervention also positions suppliers as a partner of choice of international brands, which have net-zero goals.

Conclusion

Carbon emission is a critical concern in the production of textiles, as well as business competitiveness and climate considerations. By implementing carbon footprint reduction methods with textile companies involving improved materials, use of energy, newer technologies, waste minimization, circular practices, and reporting, the manufacturers can make tangible improvements.

The recent statistics indicate the magnitude of the environmental problem and the prospects of business creativity and development. The textile learners and industry professionals should know these strategies. The future of textile manufacturing will be characterized by the adoption of carbon reduction approaches to generate both environmental and economic value.The global textile and  apparel industry continues to have a strong impact on climate change. By 2025, the sector is estimated to generate around 10% of worldwide carbon emissions. Recent industry data shows that fashion and textile activities produced close to 944 million tonnes of carbon dioxide equivalent in 2023, which was higher than the previous year. Emissions increased by about 7.5% as  clothing production expanded and the use of virgin polyester remained high, accounting for more than half of all fiber consumption. If this trend continues, total emissions from the industry could rise to around 1.24 billion tonnes by 2030. This would mean nearly a 50 % increase compared with current levels, creating serious pressure on global climate targets. Textile manufacturing is still more carbon-intensive than many transport industries, with raw material production and early processing stages responsible for the largest share of emissions.