Fabric waste is a pressing issue in the textile industry that can no longer be overlooked. This crisis doesn’t just manifest in landfills; it originates right on the factory floor. Pre-consumer waste, such as offcuts, chindi (scraps), selvages, and various sewing discards, erodes profit margins and undermines sustainability efforts.
According to Fashion for Good, India produces a staggering 7,800 kilotonnes of textile waste annually, with 42% stemming from pre-consumer sources—garment manufacturing alone accounts for 24% of this total. Despite the increasing dialogue surrounding sustainable practices, the garment industry continues to generate vast amounts of fabric waste that cannot be reused or repurposed, often ending up as recycled material.
A significant contributor to this wastage is the cutting department, where inefficiencies such as low marker efficiency and poor alignment lead to oddly shaped offcuts that are too small or irregular for conventional garment construction. Even with advanced CAD and auto-cutting technologies, it’s common to see a cutting waste rate of 10%. Once fabric is cut improperly or misaligned, reintroducing it into production is nearly impossible. Additionally, rejections from the sewing floor contribute substantially to waste due to stitching errors, incorrect assemblies, and flawed workmanship.
When dealing with small garment components—like pocket flaps or collars—quality issues such as fraying can render these pieces unusable. Furthermore, styles that involve surface ornamentation, such as embroidery or laser cuts, often generate small trimmings that are too specific to be reused, creating more irrecoverable waste.
After bulk cutting, mismatches and leftover panels are common, as inconsistent counts can leave orphaned parts that may sit unused for months before heading to waste due to their incomplete status. During final inspections, additional trims to address minor imperfections generate micro-fabric shreds, which are often contaminated with threads, tags, or glue, rendering them non-reusable.
To address this escalating issue, manufacturers are exploring solutions for fabric waste in the textile industry. Strategies include transforming scraps into yarn, upcycling surplus into new products, and collaborating with industries such as carpet manufacturing for unusable materials. Manufacturers are also embracing new cutting technologies and partnering with tech innovators to develop circular systems.
For instance, Vardhman, a major player with an annual capacity of 1.8 million shirts, operates a Renova recycling plant in Baddi, Himachal Pradesh. This facility is dedicated to converting textile waste into new fibers, which are then used to create sustainable garments. Similarly, Raymond Ltd. channels waste from its production sites into the carpet sector, effectively giving that material a second life while aiming for zero waste to landfill by 2030.
Sportking India is another example of a vertically integrated manufacturer repurposing processed waste into new products like recycled fabrics and cleaning wipes. With a turnover exceeding Rs. 1,500 crore (approximately $210 million), over half of its revenue comes from exports.
Some companies are forging partnerships with solution providers to tackle textile waste comprehensively. Arvind Ltd. has collaborated with sustainable technology firm PurFi Global LLC to establish a circularity facility in Gujarat. Targeting diverse materials like cotton and synthetics, this facility will use proprietary technology to regenerate textile waste into high-quality fibers that can be reused numerous times.
Others, like Vedant Fashions, have established processes for managing various waste streams through recyclers and local traders. Gokaldas Exports has similarly redirected non-hazardous solid wastes to authorized recyclers, achieving a recycling efficiency of 72%, with a target of zero solid waste to landfills by 2030.
Clever use of automation and smart technology is also becoming prevalent. Advances such as auto-cutting and water-jet cutters enhance precision and minimize offcuts. For example, Lux Industries has implemented high-tech machinery that significantly reduces waste during fabric cutting. Ginni Filaments has introduced targeted measures, such as installing a Card Web Reducer to minimize fabric width, reporting substantial reductions in waste.
Gokaldas Exports has optimized its fabric-handling processes through a comprehensive barcoding system that tracks materials from arrival to production. Digital width checks, shade identification via QR labels, and a centralized CAD system for automated marker making further enhance efficiency.
Overall, adopting solutions for fabric waste in the textile industry requires innovation, collaboration, and a commitment to sustainability throughout the supply chain. The industry must embrace these strategies to foster a circular economy.
