It is no longer a future concern—climate change is touching every industry and textiles are included. International fashion and textile production is reported to account for about 8–10 percent of all carbon emissions, greater than those from flights and international maritime shipping.
Yet, will the textile industry using dye vats, steam boilers, synthetic fibres and transport around the world ever become carbon neutral?
You are now entering the world of carbon-zero textiles—where being green competes with technology and players in the industry are considering new ways to create, finish and deliver fabrics.
What Do We Mean by “Carbon-Zero” in Textiles?
Carbon-zero or net-zero, we mean by this the total amount of greenhouse gases ( GHGs ) emitted is eliminated through the reduction efforts or carbon removal techniques. In simpler term, the aim is :
“Manufacture textiles without contributing extra carbon to the earth’s atmosphere.”
Less emissions isn’t the goal; instead, the target is to equalize what is produced with what is stored or avoided.
Where do the emissions come from in the textile industry?
To understand how to reduce emissions, we first need to know where they come from.
Major Sources of Carbon Emissions:
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Fibre Production:
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Synthetic fibres like polyester are derived from fossil fuels.
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Even cotton has a carbon footprint due to fertilisers, irrigation, and field emissions.
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Spinning & Weaving:
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High energy consumption in spinning frames, air jet looms, etc.
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Often powered by coal- or diesel-based electricity.
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Wet Processing (Dyeing, Printing, Finishing):
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Most carbon-intensive stage.
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Uses steam, chemicals, and massive water resources.
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Transport & Logistics:
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Raw material to spinner → spinner to processor → processor to retailer.
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Typically involves fossil-fuel-based shipping and trucking.
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Packaging & Distribution:
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Single-use plastics, cardboard boxes, air freight = high CO₂ per kg.
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Can the Industry Really Go Carbon-Zero?
The short answer: Yes, but it’s complicated.
Carbon-zero textiles are possible through a combination of renewable energy, green chemistry, efficient machinery, and closed-loop systems. Let’s look at how it’s being done.
Real-World Examples: Who’s Leading the Way?
Arvind Limited (India)
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Installed biomass boilers to replace coal in dyeing.
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Solar energy covers part of their manufacturing plant’s power demand.
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Invested in zero-liquid-discharge (ZLD) systems to reuse all water.
Lenzing (Austria)
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Produces TENCEL™ fibres from sustainably sourced wood pulp.
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Operates on carbon-neutral manufacturing for selected fibre types.
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Closed-loop solvent systems recover 99% of the used chemicals.
Levi’s
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Reduced water use by over 96% using ozone finishing and enzyme-based softeners.
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Working with regen cotton farmers to lower Scope 3 emissions.
IKEA
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All textiles aim to be from recycled or sustainably sourced fibres by 2030.
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Committed to climate-positive operations by using clean energy and efficient logistics.
Key Technologies Enabling Carbon-Zero Textiles
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Bio-Energy Boilers
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Replaces coal with rice husk, wood pellets, or bio-oil.
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Already adopted in several Indian mills.
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Enzyme-Based Wet Processing
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Reduces chemical load and lowers heat requirements.
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Used in scouring, bleaching, and even dye fixation.
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AI-Driven Energy Monitoring
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Real-time sensors optimise dyeing and drying machines.
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Reduces electricity and steam wastage by 10–30%.
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Carbon Capture at Source
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Technologies to absorb CO₂ directly from boiler flue gases.
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Still costly, but pilot trials underway in denim plants.
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Renewable Energy Switchover
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Solar rooftops, wind power for spinning units.
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Many large mills in Tamil Nadu already produce 20–50% of power renewably.
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Challenges on the Road to Zero
Despite these innovations, going carbon-zero isn’t easy.
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Cost: Renewable energy, automation, and eco-chemicals require upfront capital.
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Supply chain complexity: Every vendor, dyer, spinner must align.
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Carbon accounting: Measuring exact emissions isn’t always easy or transparent.
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Raw material dependency: Fossil-derived fibres like polyester still dominate the market.
Yet, with regulations tightening globally and customers demanding cleaner fashion, companies are being pushed to act.
What Can Students and Professionals Do?
If you're a textile student or professional, your role matters more than you think.
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Understand Life Cycle Assessments (LCA): Know how to measure carbon from fibre to fabric.
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Promote cleaner processes: Learn and suggest enzyme use, low-liquor dyeing, or heat recovery systems.
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Get skilled in sustainable certifications: GOTS, OEKO-TEX, Bluesign, Higg Index — these are becoming mandatory knowledge.
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Encourage change in your workplace: Even switching to LED lighting or optimising machine loading reduces footprint.
Is Carbon-Zero the Future of Fashion?
Yes—and the shift is already happening.
Fashion brands are now being scored for their carbon impact. Retailers prefer vendors with green certifications. Even government tenders are adding sustainability clauses.
Carbon-zero isn't just an environmental dream — it's becoming a business necessity.
Why Carbon Accounting Is Crucial in Textiles
A major challenge for manufacturers is to aim for carbon neutrality, but the actual challenge is knowing how much CO₂ they're actually producing. This is where carbon accounting or GHG inventorying comes in.
Carbon emissions are classified under:
- Scope 1: Direct emissions from facilities (e.g. boilers, vehicles)
- Scope 2: Indirect emissions from purchased electricity
- Scope 3: All other emissions (raw material sourcing, shipping, employee travel, etc.)
Most textile companies find that Scope 3 emissions add up to 70% or more of everything they emit. The process covers growing cotton, making synthetic fibres, dye chemistry, packaging the goods, arranging logistics and consumer use of the products.
Because of this, brands have to work together with suppliers, transport partners and customers to reduce carbon emissions.
Policy Pressure: Carbon Regulations are Coming
Governments and regulators are no longer sitting quietly. Textile brands are being asked to report and reduce emissions across their supply chains.
Some key policy developments:
- EU Green Deal & CBAM: Starting in 2026, EU importers must pay a “carbon tax” on imported products with high emissions—including textiles.
- India’s Carbon Market: The Bureau of Energy Efficiency (BEE) is implementing a carbon trading mechanism, likely to impact large mills.
- SBTi (Science-Based Targets initiative): Many global brands (like H&M, Adidas) have committed to reducing emissions by 30–50% by 2030.
This policy landscape means that manufacturers who don’t adapt may lose major clients or face penalties.
Digital Tools Making Carbon Tracking Easier
Technology is playing a big role in tracking emissions more precisely. Companies are investing in tools like:
- Higg Index (by SAC): Measures environmental impact of materials, manufacturing, and facilities
- Bluesign® System: Tracks chemical usage and carbon intensity
- LCA Software: Tools like GaBi and SimaPro help calculate emissions at each product life stage
Some Indian start-ups are also developing simpler carbon footprint calculators for MSME textile units.
Even digital twins of factories are being used to simulate emission scenarios and plan upgrades.
How Circular Economy Fits into Carbon-Zero
Reducing carbon isn't just about clean energy—it’s about changing how products are made and disposed of.
Circular strategies helping reduce emissions:
- Recycling polyester garments back into fibre (e.g. using chemical recycling like depolymerisation)
- Designing for disassembly, making it easier to recycle fabrics
- Refurbishing and resale models—so fewer garments are dumped in landfills
Each time a fibre or fabric is reused instead of created new, carbon emissions are avoided.
For example:
- Producing recycled polyester emits up to 60% less CO₂ than virgin polyester
- Refurbishing garments saves both emissions and water
Brands like Patagonia and The North Face have already adopted resale systems. In India, platforms like Refash are encouraging upcycled fashion.
A Cultural Shift in the Making
Carbon-zero is not just a technological change—it’s a mindset change.
Students and young professionals entering the industry today are the future sustainability leaders. Companies are looking for people who understand:
- Sustainable sourcing
- Material science with an eco-focus
- Energy-efficient processing
- Digital monitoring tools
- Cross-functional collaboration (QA, production, CSR)
Educational institutes like NIFT, IIT-Delhi, and ATIRA are now including sustainability modules in their textile curriculum. GATE and other textile exams may also begin reflecting these topics in upcoming years.
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❓ Frequently Asked Questions
Q1: Is it really possible to make 100% carbon-zero garments?
Q2: What’s the difference between carbon-neutral and carbon-zero?
Q3: Are recycled fibres considered carbon-zero?
Q4: Can small mills go carbon-zero?
Q5: Are there any carbon-zero textile certifications?