Fashion’s Resources:
How Sustainable Are They?

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What is Sustainability in Clothing Manufacturing?

Sustainability is defined as “development that meets the needs of the present without compromising the ability of future generations to meet their own needs” [1]. In the context of clothing manufacturing, this means designing, producing, and distributing apparel with minimal environmental harm, responsible resource use, and ethical labor practices.

Unlike conventional manufacturing—often associated with high energy consumption, chemical-intensive processes, and excessive waste—sustainable clothing production prioritizes efficiency, transparency, and pollution reduction (see the following comparison table).

The industry’s reliance on natural and synthetic resources raises critical questions about sustainability. As consumer awareness grows, fashion brands are facing increasing pressure to ensure ethical sourcing, responsible production, and transparency in their supply chains [2].

Comparison Table: Conventional vs. Sustainable Manufacturing Practices [3,4]

Key Sustainable Practices in Clothing Manufacturing

As fashion’s environmental footprint becomes impossible to ignore, manufacturers are adopting resource-conscious strategies to reduce waste, conserve energy, and limit pollution. But are these measures truly enough to transform an industry built on overproduction?

Use of Sustainable Materials

Sustainable manufacturers are prioritizing raw materials with lower environmental footprints and integrating circular economy principles.

Processing natural fibers in a textile facility, where raw materials are prepared for sustainable fabric production.

Organic Cotton

Grown without pesticides or synthetic fertilizers, organic cotton conserves soil health, reduces water contamination, and supports biodiversity [5,6]. Compared to conventional cotton, organic cultivation significantly reduces water usage—by up to 91%—making it a more sustainable choice [7]. Brands like Patagonia utilize GOTS-certified organic cotton, ensuring responsible agricultural practices [5,6,8]. However, its lower yield and higher cost compared to conventional cotton remain challenges for widespread adoption.

Alpaca Wool

Alpaca wool stands out as one of the most sustainable natural fibers due to its minimal environmental impact [9,10]. Alpacas have gentle grazing habits that preserve soil health, and their wool is naturally thermoregulating, hypoallergenic, lightweight, and moisture-wicking [9,10,11,12,13]. Additionally, alpaca fibers have antimicrobial properties, making them resistant to odors and requiring fewer washes than other natural fibers [14].

Bamboo

Bamboo is known for its rapid growth and renewability, requiring minimal water and pesticides. It also produces more oxygen and contributes to carbon sequestration by absorbing more carbon dioxide than conventional trees [8,15,16]. However, bamboo’s sustainability is highly dependent on processing methods. Mechanically processed bamboo retains its eco-friendly qualities, but chemical processing—commonly used for producing bamboo viscose—can negate its environmental benefits due to the use of toxic solvents [17].

Recycled and Upcycled Textiles

Recycled polyester & nylon, made from plastic waste, significantly reduce dependence on virgin fossil fuels. Brands like American Apparel and Adidas integrate these materials into their product lines [2,8,4]. Upcycling, on the other hand, repurposes pre-consumer textile waste (e.g., fabric scraps) into new garments, minimizing landfill contributions [2].

While recycling and upcycling contribute to waste reduction, they are often criticized for perpetuating the linear economy model. Relying solely on recycling without addressing overconsumption may not lead to long-term sustainability [7].

Eco-Conscious Dyeing & Textile Processing

Dyeing and finishing processes are some of the most polluting stages in textile manufacturing, often involving toxic chemicals and high water consumption. In response, sustainable manufacturers are embracing eco-conscious dyeing techniques to reduce environmental harm.

Natural Dyes: A Return to Traditional Methods

Derived from plants, minerals, and insects, natural dyes offer a biodegradable, non-toxic alternative to synthetic colorants. Common sources include indigo (blue), cochineal (red), turmeric (yellow), and madder (orange and red hues) [3]. By avoiding heavy metals and petrochemicals, natural dyes significantly reduce environmental toxicity.

Organic indigo dye extraction process.

Waterless Dyeing Technologies

Innovative technologies like CO₂ dyeing (DyeCoo) and Air Dye drastically reduce water usage and pollution by using pressurized CO₂ or air for dyeing processes. These methods eliminate wastewater and minimize chemical use, offering a more sustainable alternative to conventional dyeing [18].

While waterless dyeing is environmentally advantageous, the high cost of machinery and technology access remains a barrier for small-scale manufacturers.

Ozone Washing: A Sustainable Alternative for Denim

Primarily used in denim production, ozone washing reduces water and chemical usage while achieving the desired faded look. This technique eliminates harmful bleaches and increases dye uptake efficiency to 98%, while cutting chemical consumption by up to 50% compared to traditional methods [18]. This technique exemplifies how sustainable innovation can maintain product aesthetics without environmental compromise. A prime example is Levi’s Water<Less™ technology, which incorporates ozone washing, nanobubble application, and reduced rinsing cycles to minimize water consumption. This innovation has allowed Levi’s to cut water use by up to 96% in denim finishing processes—a significant step toward reducing fashion’s water footprint [19].

Primarily used in denim production, ozone washing reduces water and chemical usage while achieving the desired faded look. This technique eliminates harmful bleaches and increases dye uptake efficiency to 98%, while cutting chemical consumption by up to 50% compared to traditional methods [18]. This technique exemplifies how sustainable innovation can maintain product aesthetics without environmental compromise. A prime example is Levi’s Water<Less™ technology, which incorporates ozone washing, nanobubble application, and reduced rinsing cycles to minimize water consumption. This innovation has allowed Levi’s to cut water use by up to 96% in denim finishing processes—a significant step toward reducing fashion’s water footprint [19].

Is it feasible for the fashion industry to fully transition to these sustainable dyeing methods, or will conventional practices continue to dominate?

Above: An ozone washing machine used in denim manufacturing, designed to reduce water and chemical consumption in the finishing process. Down: A pair of jeans faded using ozone treatment, achieving a worn-in look while minimizing environmental impact. Image extracted from Nayak et al. (2024) [3].

On the left: An ozone washing machine used in denim manufacturing, designed to reduce water and chemical consumption in the finishing process. On the right: A pair of jeans faded using ozone treatment, achieving a worn-in look while minimizing environmental impact. Image extracted from Nayak et al. (2024) [3].

Energy Efficiency and Carbon Emission Reduction

The fashion industry contributes nearly 10% of global carbon emissions [4]. To combat this, manufacturers are adopting energy-efficient systems and renewable energy sources.

Renewable Energy in Manufacturing

Many manufacturers are transitioning to solar, wind, and biomass energy to power their factories, reducing reliance on fossil fuels and lowering carbon emissions [3]. However, implementing renewable energy systems requires significant upfront investment and infrastructure, limiting accessibility for smaller brands.

Automation and Robotics in Textile Production

Automation and robotics enhance productivity while optimizing energy use and minimizing technologies like AI-assisted material handling and robotic sewing improve efficiency and reduce fabric waste [3]. Yet, increased automation raises ethical concerns about job displacement.

Proximity Manufacturing: A Low-Carbon Alternative

Producing garments closer to the consumer markets significantly reduces transportation-related carbon emissions while supporting local economies [4]. This approach aligns with the growing trend of localized production and on-demand manufacturing.

While these innovations effectively reduce emissions, the industry's reliance on energy-intensive processes remains a challenge. Can renewable energy and advanced technologies truly decarbonize the fashion industry?

Water Management and Waste Recycling

Water scarcity is a growing crisis, and the textile industry remains one of the largest water consumers and polluters.

Waterless Dyeing & Wastewater Recycling

• Waterless dyeing (DyeCoo, Air Dye) eliminates wastewater, reducing pollution [8].
• Wastewater recycling allows manufacturers to reuse water in production cycles, cutting freshwater consumption and environmental contamination [8].

Zero-Waste Design & Circular Fashion

• Zero-waste pattern cutting minimizes fabric scraps during garment production.
• Circular design promotes repairability, recycling, and garment longevity, aligning with a closed-loop fashion system [6].

While these efforts help, critics argue that true sustainability requires deeper systemic change, not just technological fixes.

Deposits of residual textile fibers destined for recycling processes.

Can the Fashion Industry Truly Become Sustainable?

The road to sustainable clothing manufacturing is complex. While brands like Patagonia, Levi’s, and Adidas are pioneering change, greenwashing remains a major concern. The industry must go beyond marketing claims and adopt genuine circular economy models to achieve long-term sustainability.

The Power of Consumer Choice

Consumers play a critical role in driving demand for ethical fashion. By choosing sustainable materials, supporting transparent brands, and rejecting fast fashion, we can collectively reshape the fashion industry’s environmental impact.

Are brands truly committed to sustainability, or are they just capitalizing on the trend? The responsibility doesn’t just lie with manufacturers—it lies with all of us.

Authors & Researchers

Jordy Munarriz

Environmental Engineer with a master's degree in renewable energy and a specialization in sustainability. Researcher and writer, he combines his technical knowledge with his passion for environmental communication, addressing topics of ecological impact and sustainable solutions in the textile industry and beyond.