Textination Newsline

In a world first for the fashion industry, in October 2020 twelve pioneering players came together to break new ground by demonstrating a circular model for commercial garment production. Over more than three years, textile waste was collected and sorted, and regenerated into a new, man-made cellulosic fiber that looks and feels like cotton – a “new cotton” – using Infinited Fiber Company’s textile fiber regeneration technology.
 
The pioneering New Cotton Project launched in October 2020 with the aim of demonstrating a circular value chain for commercial garment production. Through-out the project the consortium worked to collect and sort end-of-life textiles, which using pioneering Infinited Fiber technology could be regenerated into a new man-made cellulosic fibre called Infinna™ which looks and feels just like virgin cotton. The fibres were then spun into yarns and manufactured into different types of fabric which were designed, produced, and sold by adidas and H&M, making the adidas by Stella McCartney tracksuit and a H&M printed jacket and jeans the first to be produced through a collaborative circular consortium of this scale, demonstrating a more innovative and circular way of working for the fashion industry.
 
As the project completes in March 2024, the consortium highlights eight key factors they have identified as fundamental to the successful scaling of fibre-to-fibre recycling.

The wide scale adoption of circular value chains is critical to success
Textile circularity requires new forms of collaboration and open knowledge exchange among different actors in circular ecosystems. These ecosystems must involve actors beyond traditional supply chains and previously disconnected industries and sectors, such as the textile and fashion, waste collection and sorting and recycling industries, as well as digital technology, research organisations and policymakers. For the ecosystem to function effectively, different actors need to be involved in aligning priorities, goals and working methods, and to learn about the others’ needs, requirements and techno-economic possibilities. From a broader perspective, there is also a need for a more fundamental shift in mindsets and business models concerning a systemic transition toward circularity, such as moving away from the linear fast fashion business models. As well as sharing knowledge openly within such ecosystems, it also is important to openly disseminate lessons learnt and insights in order to help and inspire other actors in the industry to transition to the Circular Economy.

Circularity starts with the design process
When creating new styles, it is important to keep an end-of-life scenario in mind right from the beginning. As this will dictate what embellishments, prints, accessories can be used. If designers make it as easy as possible for the recycling process, it has the bigger chance to actually be feedstock again. In addition to this, it is important to develop business models that enable products to be used as long as possible, including repair, rental, resale, and sharing services.

Building and scaling sorting and recycling infrastructure is critical
In order to scale up circular garment production, there is a need for technological innovation and infrastructure development in end-of-use textiles collection, sorting, and the mechanical pre-processing of feedstock. Currently, much of the textiles sorting is done manually, and the available optical sorting and identification technologies are not able to identify garment layers, complex fibre blends, or which causes deviations in feedstock quality for fibre-to-fibre recycling. Feedstock preprocessing is a critical step in textile-to-textile recycling, but it is not well understood outside of the actors who actually implement it. This requires collaboration across the value chain, and it takes in-depth knowledge and skill to do it well. This is an area that needs more attention and stronger economic incentives as textile-to-textile recycling scales up.

Improving quality and availability of data is essential
There is still a significant lack of available data to support the shift towards a circular textiles industry. This is slowing down development of system level solutions and economic incentives for textile circulation. For example, quantities of textiles put on the market are often used as a proxy for quantities of post-consumer textiles, but available data is at least two years old and often incomplete. There can also be different textile waste figures at a national level that do not align, due to different methodologies or data years. This is seen in the Dutch 2018 Mass Balance study reports and 2020 Circular Textile Policy Monitoring Report, where there is a 20% difference between put on market figures and measured quantities of post-consumer textiles collected separately and present in mixed residual waste. With the exception of a few good studies such as Sorting for Circularity Europe and ReFashion’s latest characterization study, there is almost no reliable information about fibre composition in the post-consumer textile stream either. Textile-to-textile recyclers would benefit from better availability of more reliable data. Policy monitoring for Extended Producer Responsibility schemes should focus on standardising reporting requirements across Europe from post-consumer textile collection through their ultimate end point and incentivize digitization so that reporting can be automated, and high-quality textile data becomes available in near-real time.

The need for continuous research and development across the entire value chain
Overall, the New Cotton Project’s findings suggest that fabrics incorporating Infinna™ fibre offer a more sustainable alternative to traditional cotton and viscose fabrics, while maintaining similar performance and aesthetic qualities. This could have significant implications for the textile industry in terms of sustainability and lower impact production practices. However, the project also demonstrated that the scaling of fibre-to-fibre recycling will continue to require ongoing research and development across the entire value chain. For example, the need for research and development around sorting systems is crucial. Within the chemical recycling process, it is also important to ensure the high recovery rate and circulation of chemicals used to limit the environmental impact of the process. The manufacturing processes also highlighted the benefit for ongoing innovation in the processing method, requiring technologies and brands to work closely with manufacturers to support further development in the field.

Thinking beyond lower impact fibres
The New Cotton Project value chain third party verified LCA reveals that the cellulose carbamate fibre, and in particular when produced with a renewable electricity source, shows potential to lower environmental impacts compared to conventional cotton and viscose. Although, it's important to note that this comparison was made using average global datasets from Ecoinvent for cotton and viscose fibres, and there are variations in the environmental performance of primary fibres available on the market. However, the analysis also highlights the importance of the rest of the supply chain to reduce environmental impact. The findings show that even if we reduce the environmental impacts by using recycled fibres, there is still work to do in other life cycle stages. For example; garment quality and using the garment during their full life span are crucial for mitigating the environmental impacts per garment use.
          
Citizen engagement
The EU has identified culture as one of the key barriers to the adoption of the circular economy within Europe. An adidas quantitative consumer survey conducted across three key markets during the project revealed that there is still confusion around circularity in textiles, which has highlighted the importance of effective citizen communication and engagement activities.

Cohesive legislation
Legislation is a powerful tool for driving the adoption of more sustainable and circular practices in the textiles industry. With several pieces of incoming legislation within the EU alone, the need for a cohesive and harmonised approach is essential to the successful implementation of policy within the textiles industry. Considering the link between different pieces of legislation such as Extended Producer Responsibility and the Ecodesign for Sustainable Products Regulation, along with their corresponding timeline for implementation will support stakeholders from across the value chain to prepare effectively for adoption of these new regulations.

The high, and continuously growing demand for recycled materials implies that all possible end-of-use textiles must be collected and sorted. Both mechanical and chemical recycling solutions are needed to meet the demand. We should also implement effectively both paths; closed-loop (fibre-to-fibre) and open -loop recycling (fibre to other sectors). There is a critical need to reconsider the export of low-quality reusable textiles outside the EU. It would be more advantageous to reuse them in Europe, or if they are at the end of their lifetime recycle these textiles within the European internal market rather than exporting them to countries where demand is often unverified and waste management inadequate.

Overall, the learnings spotlight the need for a holistic approach and a fundamental mindset shift in ways of working for the textiles industry. Deeper collaboration and knowledge exchange is central to developing effective circular value chains, helping to support the scaling of innovative recycling technologies and increase availability of recycled fibres on the market. The further development and scaling of collecting and sorting, along with the need to address substantial gaps in the availability of quality textile flow data should be urgently prioritised. The New Cotton Project has also demonstrated the potential of recycled fibres such as Infinna™ to offer a more sustainable option to some other traditional fibres, but at the same time highlights the importance of addressing the whole value chain holistically to make greater gains in lowering environmental impact. Ongoing research and development across the entire value chain is also essential to ensure we can deliver recycled fabrics at scale in the future.

The New Cotton Project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 101000559.

From the perspective of European consumption, textiles have on average the fourth highest negative life cycle impact on the environment and climate change, after food, housing and mobility. A shift to a circular textile production and consumption system with longer use, and more reuse and recycling could reduce those impacts along with reductions in overall consumption. One important measure is circular design of textiles to improve product durability, repairability and recyclability and to ensure the uptake of secondary raw materials in new products.

Key messages

• In 2019, the EU textile and clothing sector had a turnover of EUR162 billion, employing over 1.5 million people across 160,000 companies. As was the case in many sectors, between 2019 and 2020, the COVID-19 crisis decreased turnover by 9% for textiles as a whole and by 17% for clothing.
• In 2020, textile consumption in Europe had on average the fourth highest impact on the environment and climate change from a global life cycle perspective. It was the consumption area with the third highest impact on water and land use, and the fifth highest in terms of raw material use and greenhouse gas emissions.
• To reduce the environmental impacts of textiles, a shift towards circular business models, including circular design, is crucial. This will need technical, social and business model innovation, as well as behavioural change and policy support.
• Circular design is an important enabler of the transition towards sustainable production and consumption of textiles through circular business models. The design phase plays a critical role in each of the four pathways to achieving a circular textile sector: longevity and durability; optimised resource use; collection and reuse; and recycling and material use.

Textiles are identified as a key value chain in the EU circular economy action plan and will be addressed in the forthcoming European Commission’s 2022 EU strategy for sustainable and circular textiles and EU sustainable products initiative. This briefing aims to improve our understanding of the environmental and climate impacts of textiles from a European perspective and to identify design principles and measures to increase circularity in textiles. It is underpinned by a report from the EEA’s European Topic Centre on Circular Economy and Resource Use available here.

1. Production, trade and consumption of textiles
Textiles is an important sector for the EU economy. In 2019, the EU textile and clothing sector had a turnover of EUR162 billion, employing over 1.5 million people in 160,000 companies. As was the case for many sectors, between 2019 and 2020, the COVID-19 health and economic crisis decreased turnover by 9% for textiles as a whole and by 17% for clothing (Euratex, 2021).

In 2020, 6.9 million tonnes of finished textile products were produced in the EU-27. EU production specialises in carpets, household textiles and other textiles (including non-woven textiles, technical and industrial textiles, ropes and fabrics). In addition to finished products, the EU produces intermediate products for textiles, such as fibres, yarns and fabrics (Köhler et al., 2021).

The textiles sector is labour intensive compared with others. Almost 13 million full-time equivalent workers were employed worldwide in the supply chain to produce the amount of clothing, textiles and footwear consumed in the EU-27 in 2020. This makes the textiles sector the third largest employer worldwide, after food and housing. Most production takes place in Asia, where low production costs come at the expense of workers’ health and safety.
 
Textiles are highly globalised, with Europe being a significant importer and exporter. In 2020, 8.7 million tonnes of finished textile products, with a value of EUR125 billion, were imported into the EU-27. Clothing accounts for 45% of imports in terms of volume, followed by household textiles, other textiles and footwear (Eurostat, 2021a). The EU imports mainly from China, Bangladesh and Turkey, and exports mainly to the United Kingdom, Switzerland and the United States (Euratex, 2020).

Consumption
European households consume large amounts of textile products. In 2019, as in 2018, Europeans spent on average EUR600 on clothing, EUR150 on footwear and EUR70 on household textiles (Köhler et al., 2021; Eurostat, 2021b).

The response to the COVID-19 pandemic, involving stay-at-home measures and the closure of companies and shops, decreased textile production and demand overall (Euratex, 2021). As a result, the consumption of clothing and footwear per person decreased in 2020, relative to 2019, while the consumption of household textiles slightly increased. Average textile consumption per person amounted to 6.0kg of clothing, 6.1kg of household textiles and 2.7kg of shoes in 2020 (see Figure 1).

Apart from this COVID-related drop in consumption in 2020, the estimated consumption of clothing and footwear stayed relatively constant over the last decade, with slight fluctuations between years (see Figure 2). Similarly, the consumption of household textiles was also relatively steady, with a slight increase over the decade.

When calculating the ‘estimated consumption’ based on production and trade data from 2020, and excluding industrial/technical textiles and carpets, total textile consumption is 15kg per person per year, consisting of, on average:

• 6.0kg of clothing
• 6.1kg of household textiles
• 2.7kg footwear.

For 2020, this amounts to a total consumption of 6.6 million tonnes of textile products in Europe. Textile consumption estimates are uncertain, as they vary by study, often using different scopes and calculation methods.

2. Environmental and climate impacts of textiles
The production and consumption of textiles has significant impacts on the environment and climate change. Environmental impacts in the production phase result from the cultivation and production of natural fibres such as cotton, hemp and linen (e.g. use of land and water, fertilisers and pesticides) and from the production of synthetic fibres such as polyester and elastane (e.g. energy use, chemical feedstock) (ETC/WMGE, 2021b). Manufacturing textiles requires large amounts of energy and water and uses a variety of chemicals across various production processes. Distribution and retail are responsible for transport emissions and packaging waste.

During use and maintenance — washing, drying and ironing — electricity, water and detergents are used. Chemicals and microfibres are also emitted into the waste water. Meanwhile, textiles contribute to significant amounts of textile waste. At the end of their life, textiles often end up in general waste and are incinerated or landfilled. When textile waste is collected separately, textiles are sorted and reused, recycled or disposed of, depending on their quality and material composition. In 2017, it was estimated that less than 1% of all textiles worldwide are recycled into new products (Ellen MacArthur Foundation, 2017).

To illustrate the magnitude of the impacts of textile consumption on raw material use, water and land use and greenhouse gas emissions compared with other consumption categories, we have updated our calculations of the life cycle environmental and climate impacts in the EU. We used input-output modelling based on data from the Exiobase database and Eurostat. In line with the reduced textile consumption level in 2020 because of the COVID-19 pandemic, the environmental impacts decreased from 2019 to 2020.

Raw material use
Large amounts of raw materials are used for textile production. To produce all clothing, footwear and household textiles purchased by EU households in 2020, an estimated 175 million tonnes of primary raw materials were used, amounting to 391kg per person. Roughly 40% of this is attributable to clothes, 30% to household textiles and 30% to footwear. This ranks textiles as the fifth highest consumption category in Europe in terms of primary raw material use (see Figure 3).

The raw materials used include all types of materials used in producing natural and synthetic fibres, such as fossil fuels, chemicals and fertilisers. It also includes all building materials, minerals and metals used in the construction of production facilities. Transport and retail of the textile products are included as well. Only 20% of these primary raw materials are produced or extracted in Europe, with the remainder extracted outside Europe. This shows the global nature of the textiles value chain and the high dependency of European consumption on imports. This implies that 80% of environmental impacts generated by Europe’s textile consumption takes place outside Europe. For example, cotton farming, fibre production and garment construction mostly take place in Asia (ETC/WMGE, 2019).

Water use
Producing and handling textiles requires large quantities of water. Water use distinguishes between ‘blue’ water (surface water or groundwater consumed or evaporated during irrigation, industry processes or household use) and ‘green’ water (rain water stored in the soil, typically used to grow crops) (Hoekstra et al., 2012).

To produce all clothing, footwear and household textiles purchased by EU households in 2020, about 4,000 million m³ of blue water were required, amounting to 9m³ per person, ranking textiles’ water consumption in third place, after food and recreation and culture (see Figure 4).

Additionally, about 20,000 million m³ of green water was used, mainly for producing cotton, which amounts to 44m³ per person. Blue water is used fairly equally in producing clothing (40%), footwear (30%) and household and other textiles (30%). Green water is mainly consumed in producing clothing (almost 50%) and household textiles (30%), of which cotton production consumes the most.

Water consumption for textiles consumed in Europe mostly takes place outside Europe. It is estimated that producing 1kg of cotton requires about 10m³ of water, typically outside Europe (Chapagain et al., 2006).

Land use
Producing textiles, in particular natural textiles, requires large amounts of land. The land used in the supply chain of textiles purchased by European households in 2020 is estimated at 180,000 km², or 400m² per person. Only 8% of the land used is in Europe. Over 90% of the land use impact occurs outside Europe, mostly related to (cotton) fibre production in China and India (ETC/WMGE, 2019). Animal-based fibres, such as wool, also have a significant land use impact (Lehmann et al., 2018). This makes textiles the sector with the third highest impact on land use, after food and housing (see Figure 5). Of this, 43% is attributable to clothes, 35% to footwear (including leather shoes, which have a high land use impact because of the need for cattle pasture) and 23% to household and other textiles.

Greenhouse gas emissions
The production and consumption of textiles generate greenhouse gas emissions, in particular from resource extraction, production, washing and drying, and waste incineration. In 2020, producing textile products consumed in the EU generated greenhouse gas emissions of 121 million tonnes carbon dioxide equivalent (CO₂e) in total, or 270kg CO₂e per person. This makes textiles the household consumption domain responsible for the fifth largest impact on climate change, after housing, food, transport and mobility, and recreation and culture (see Figure 6). Of this, 50% is attributable to clothes, 30% to household and other textiles, and 20% to footwear. While greenhouse gas emissions have a global effect, almost 75% are released outside Europe, mainly in the important textile-producing regions in Asia (ETC/WMGE, 2019).

About 80% of the total climate change impact of textiles occurs in the production phase. A further 3% occurs in distribution and retail, 14% in the use phase (washing, drying and ironing), and 3% during end of life (collection, sorting, recycling, incineration and disposal) (ECOS, 2021; Östlund et al., 2020).

Textiles made from natural fibres, such as cotton, generally have the lowest climate impact. Those made from synthetic fibres (especially nylon and acrylic) generally have a higher climate impact because of their fossil fuel origin and the energy consumed during production (ETC/WMGE, 2021b; Beton et al., 2014).

3. Design as an enabler of circular business models for textiles
To reduce the environmental and climate change impacts of textiles, shifting towards circular business models is crucial to save on raw materials, energy, water and land use, emissions and waste (ETC/WMGE, 2019). Implementing and scaling circular business models requires technical, social and business model innovation; as well as enablers from policy, consumption and education (EEA, 2021).

Circular design is an important component of circular business models for textiles. It can ensure higher quality, longer lifetimes, better use of materials, and better options for reuse and recycling. While it is important to enable the recycling and reuse of materials, life-extending strategies, such as design for durability, ease of reuse, repair and remanufacturing, should be prioritised. Preventing the use of hazardous chemicals and limiting toxic emissions and release of microplastics at all life cycle stages should be incorporated into product design.

Designing for circularity is the most recent development in design for sustainability. Expanding a technical and product-centric focus to a focus on large-scale system-level changes (considering both production and consumption systems) shows that this latest development requires many more disciplines than traditional engineering design. Product design as a component of a circular business model depends on consumer behaviour and policy to realise its potential and enable implementation. Figure 7 shows the linkages between the circular business model, product design, consumer behaviour and policy. All are needed to slow down and close the loop, making it circular.

How can the major sustainability challenges in the textile industry be met? The textile services industry, whose business model has always been based on durability and re-use, has an important role to play here as ambassador. In the run-up to Texcare International, Elena Lai, Secretary General European Textile Services Association (ETSA), talks about these challenges and her expectations for Texcare International from 27 November to 1 December 2021.

The textile sector was identified as a priority sector in the European Green Deal and in the Circular Economy Action Plan. What are the implications for the European textile services industry?
Elena Lai: We are in a truly historic and exciting time for the textile services industry. We are all well-aware that our industry is the key to providing sustainable solutions and ecofriendly best practice. We had a series of webinars at ETSA dedicated to sustainability and circular economy being key elements of the Green Deal and our larger companies such as industrial laundries, key textile manufacturers and innovative machinery companies, are all up to the task and providing effective solutions. Our national associations too, members of ETSA, are all working synergistically to exchange their best ways forward, in Europe and beyond as we have also partners from the US. These efforts within ETSA’s value chain make us really proud and eager to go the extra mile, guiding our members also towards those areas which seem to be the most challenging. For instance, the new EU Climate Law, which calls for 55% CO₂ reductions by 2030: this means that European industries will all have to do better to make us reach these targets in less than nine years. We know ETSA could represent the right network to identify the best way forward on this issue and truly perform and deliver what the EU is advocating for.

How can the textile services industry contribute to achieving circular economy in the textile industry?
Elena Lai: The business model of textile services is inherently circular. By having a business model which is focused on renting and reusing textiles we can see a litany of benefits that it can offer to the EU’s Circular Economy Action Plan. Firstly, in renting textiles. Through rented textile services, textile service companies can extend the lifecycle of products and thus reduce the amount of production that is necessary to occur in the first place, while also reducing the amount of wastewater and energy needed in the laundry process. Secondly, through re-use and repair textile products can remain in consumer hands for longer, which is paramount as our industry is one that battles against planned obsolescence. Both of these are important pillars to our industries that will help both consumers and the planet. Lastly, by continuing to expand recycling and upcycling we can minimise waste, ensuring that a product stays inside the European economy as long as possible. These are all important steps and help us do our part to help Europe reach its emissions and sustainability goals.

Textile recycling is a very important point. How do you think the textile recycling rate can be increased?
Elena Lai: The Commission will mandate separate waste sorting of textiles by the year 2025, thus recycling, upcycling and end of life re-use must be improved. A ban on the burning of unused textiles will also soon take effect, this will incentivise further recycling and waste reduction. Fundamentally what we in textiles services need to do is to continue to reduce, re-use and recycle. We can increase the rate of recycling by making consumers aware of rented textiles and textile services so to increase the public demand for such services.

How can sustainability in textile services be further improved?
Elena Lai: In order to boost sustainability in our industry we need to build on the existing culture of innovation and entrepreneurship where exciting, new, out-of-the-box ideas can be developed and refined. EU programs like Horizon Europe, which emphasise green and digital solutions to common problems are an excellent way to empower citizens, textile service firms and local communities to take the initiative and take matters into their own hands. The EU’s Due Diligence legislation is one example of somewhere we can see both consumers and firms come together and take proactive action to improve sustainability, not only in textiles and textile services, but in European industry more broadly. To put it clearly, we have to strengthen our technological innovation while also empowering consumers, authorities and textile service firms, we believe our work at the EU level helps to make this a reality.

How does ETSA promote new projects in the field of sustainability?
Elena Lai: We at ETSA have been hard at work lobbying EU policymakers for responsible legislation, while also spreading awareness of the industry’s best practice to the public. Recently ETSA has also become an EU Commission Climate Pact Ambassador. This is an exciting opportunity which will allow ETSA to work closely with European Institutions to inform and inspire real climate action amongst our members, national associations and the industry as a whole. ETSA is a platform where stakeholders, citizens, industries and European Union representatives can come together and have a dialogue on the best ways to improve Europe’s sustainability. Furthermore, we have been hard at work disseminating information on the best practice that will help Europe get to 55% emissions reductions, as well information on chemicals, waste-water, microplastics and other salient environmental issues. Our work is far from being done but we look forward to continuing to strive and advance via our focused Working Group on Environment and our webinars to make the world green and sustainable again.

What role will circular economy/sustainability play at Texcare?
Elena Lai: A central role, several European and World Leaders have underlined, is that Climate Change is the most important issue of our time and it is imperative we act now. Climate Change is also an issue with a global spill over and therefore we all have a clear incentive to find solutions and work in synergy with each other. We need future-oriented dialogue which understands the urgent need for sustainability across the entire textile value chain. ETSA in synergy with one of our members, DTV, is working hard to put together a panel at Texcare dedicated to the sustainability debate, with lots of members and participants to get engaged.

What does ETSA expect from this year's Texcare?
Elena Lai: We at ETSA are excited to be at Texcare, we think it’s a great opportunity to not only network and converse with other relevant actors in the industry but also to share best practice, concerns and most of all opportunities. Due to the pandemic we had a difficult year 2021 and this event will really enhance a stronger engagement of key actors in this sector. The need for green, sustainable and digital solutions is nonetheless imperative. We are looking forward to hearing of ways that the industry across the world not only continues to adapt to the evolving COVID situation, but also how it is embracing the green and digital transition that has been emphasised as being the futuristic approach by our EU policymakers. We at ETSA wholeheartedly look forward to this event.

Texcare International will take place from November 27 December 1, 2021 in Frankfurt am Main.