Material waste in fashion industry in Bangladesh: a mixed method study on 10 selected factories

Abstract

This study investigates the material wastage at different stages of textile and apparel production, including spinning, fabric manufacturing, apparel manufacturing, and wet processing (dyeing/finishing/washing). The spinning stage exhibits a material conversion rate of 78%, with process losses and quality-related rejections contributing to the wastage. In fabric manufacturing, the weaving process results in a material conversion rate of 92%, with factors such as poor material handling and lack of expertise leading to wastage in warping, sizing, drawing-in, weaving, and inspection sections. Apparel manufacturing consumes finished fabric at a rate of 120.4 kg for every 100 kg of final products, and the cutting section accounts for a significant 10% wastage. Sewing, finishing, and inspection sections also contribute to wastage due to various issues. In wet processing, the material conversion rate is 82%, with fabric dyeing experiencing a wastage of 21 kg per 100 kg of fabric, primarily attributed to uneven dyeing. The study underscores the importance of understanding and addressing the sources of wastage, including poor material handling, quality issues, process losses, and rejections, to enhance production efficiency and reduce costs in the textile and apparel industry. The findings emphasize the need for industry stakeholders to focus on process optimization, quality control, and improved material handling practices for a more sustainable and efficient production chain.