How to Reduce Carbon Footprint in Custom Apparel

The fashion industry is responsible for 10% of global carbon emissions annually, and India's textile sector contributes 2% of the country’s greenhouse gas emissions. Reducing these emissions is critical, especially in custom apparel, where sustainable practices can significantly lower environmental impact. Here's how businesses can achieve this:

• Choose low-impact materials: Use organic cotton, recycled polyester, or Tencel, which require fewer resources and generate less pollution. Locally sourced textiles cut emissions by up to 50%.
• Switch to eco-friendly printing methods: Direct-to-garment (DTG) printing and water-based screen printing reduce energy use, waste, and harmful chemicals.
• Improve production efficiency: Print-on-demand manufacturing avoids overproduction, while in-house production reduces transportation emissions.
• Adopt energy-efficient equipment and renewable energy: Modern machinery and solar power lower operational costs and emissions.
• Minimise waste: Repurpose fabric scraps, recycle materials, and use biodegradable or recycled packaging.

These steps not only reduce carbon emissions but also align with growing consumer demand for environmentally conscious products. By taking action, businesses in India can lead the way in reshaping the apparel industry while cutting costs and improving efficiency.

How to Run a Eco Friendly Screen Printing Shop

Select Low-Impact Materials

The materials you pick for custom apparel, including fabrics and packaging, play a big role in determining your carbon footprint. Opting for fabrics made from sustainable resources - like responsibly grown fibre crops or recycled materials - can significantly cut down emissions during production and shipping ^[3].

Use Organic and Recycled Fabrics

Recycled fabrics are a smart choice as they reduce textile waste while using less water, energy, and raw materials ^[1]. They offer an efficient way to lower emissions without compromising on quality.

Organic cotton is another great option. It consumes far less water and eliminates the need for pesticides, making it a much cleaner alternative to conventional cotton ^[2][4]. Conventional cotton, which accounts for 16% of the world’s insecticide use ^[3], has a much higher environmental impact.

Recycled polyester, crafted from plastic bottles, helps divert waste from landfills and requires fewer resources compared to creating new fibres ^[1][4]. Producing recycled polyester generates noticeably lower carbon emissions than virgin polyester ^[1].

Other sustainable options include Tencel, made from sustainably sourced wood pulp using a closed-loop process, which is nearly 50 times more absorbent than cotton ^[4]. Modal, another alternative, uses up to 20 times less water than cotton ^[3]. Econyl, a regenerated nylon made from recycled waste, also stands out for its lower water usage and reduced emissions compared to traditional nylon ^[3][4].

When choosing these materials, certifications like OEKO-TEX® Standard 100, GRS (Global Recycled Standard), and Bluesign® can help ensure the fabrics meet sustainability and safety standards ^[1].

Source Textiles Locally in India

Sourcing textiles locally is one of the most impactful ways to reduce your carbon footprint. In India, local sourcing can cut emissions by up to 50% while supporting artisan communities with fair wages and increased income opportunities ^[5].

India’s long-standing tradition of cotton farming, handloom weaving, and textile craftsmanship provides an excellent foundation for sustainable local sourcing. By blending traditional techniques with modern designs, India’s fashion industry can promote eco-friendly and ethical production ^[5].

To make local sourcing work effectively, consider partnering directly with artisan communities. This ensures fair wages and good working conditions ^[5]. Adopting innovative business practices and technologies can further strengthen India’s textile heritage while navigating the challenges of local sourcing ^[5].

Choose Recycled Packaging

Switching to recycled or biodegradable packaging is another step toward sustainability. Using options like recycled shipping boxes helps cut down waste and lowers the emissions associated with shipping. Small changes in packaging choices can make a big difference in reducing your overall carbon footprint.

Use Low-Emission Printing Methods

Switching to eco-friendly printing techniques is a smart way to reduce your carbon footprint. Different methods vary in energy consumption and waste generation, so opting for those that use less power and produce fewer emissions can significantly lower your environmental impact - all while delivering high-quality results.

"Sustainable shirt printing methods prioritize reducing environmental impact and promoting responsible manufacturing practices." ^[6]

Direct-to-Garment (DTG) Printing: A Greener Choice

DTG printing is a standout option for environmentally responsible printing. This method uses water-based inks to print designs directly onto fabric, eliminating the need for intermediate materials and reducing waste. DTG printers are also energy-efficient, outperforming traditional screen printing equipment in power usage ^[6]. The on-demand nature of DTG printing minimises overproduction, ensuring ink and materials are used efficiently.

The water-based inks used in DTG printing are biodegradable and free from harmful chemicals like phthalates and PVC ^[8]. This makes DTG printing a safer choice for the environment, aligning well with modern sustainability principles by reducing chemical waste and promoting responsible production practices ^[10].

"DTG printing aligns with the principles of green technology by integrating innovations that prioritise environmental health. The use of biodegradable, water-based inks ensures minimal ecological impact." – Matthew Rhome, DTG Industry Pioneer ^[9]

Screen Printing with Water-Based Inks

While DTG printing is highly energy-efficient, traditional screen printing can also be made more sustainable by using water-based inks. These inks have a much smaller carbon footprint - up to 3,200% lower compared to solvent-based and plastisol inks ^[13]. For businesses looking to reduce their environmental impact, this is a game-changer.

Water-based inks also emit fewer volatile organic compounds (VOCs), simplifying cleanup since they can be washed out with water instead of harsh chemical solvents. In contrast, solvent-based inks are composed entirely of VOCs, releasing harmful compounds into the atmosphere ^[12].

"Water-based inks are much more likely to be biodegradable, compostable or both, meaning that they can break down naturally over time without causing harm to the environment." – Permaset ^[11]

Modern curing equipment, such as energy-efficient conveyor dryers, further enhances the sustainability of water-based screen printing by reducing energy consumption while ensuring proper curing temperatures ^[6].

Comparing Printing Methods: Environmental Impact

To make informed decisions, it helps to compare the environmental impact of various printing techniques. Here's a quick breakdown:

Other Low-Impact Printing Methods

If you're exploring alternatives, consider these additional eco-conscious methods:

• LED UV Printing: This technique uses energy-efficient LED lights instead of mercury-vapour lamps, cutting energy use and avoiding toxic by-products ^[7].
• Sublimation Printing: By transferring dye directly onto fabric, this method avoids water usage entirely and generates minimal waste ^[6].
• Heat Transfer Printing: Modern heat presses offer precise temperature control for energy efficiency ^[6]. However, the vinyl and adhesives used are not biodegradable or easily recyclable ^[8].

Investing in energy-efficient equipment like DTG printers, conveyor dryers, and advanced heat presses can reduce operating costs while appealing to eco-conscious consumers. These choices not only benefit the planet but also position your business as a leader in sustainable practices.

Improve Production Efficiency

Streamlining production processes not only helps reduce emissions, energy consumption, and waste but also lowers costs, making operations more sustainable and cost-effective.

Print-On-Demand Production

Print-on-demand (POD) manufacturing has transformed the way custom apparel is produced. Instead of creating large quantities in advance, items are made only after customers place orders. This method significantly cuts down on overproduction, minimising waste and reducing the need for excessive packaging. In fact, POD often uses minimal and eco-friendly packaging materials, making it a more sustainable choice ^[14].

To further align with environmental goals, consider partnering with suppliers who provide organic or recycled garments and use water-based printing techniques ^[15]. This ensures that every resource - whether fabric or ink - is used thoughtfully and responsibly.

In-House Manufacturing Benefits

Centralising production under one roof offers multiple advantages, especially when it comes to reducing carbon emissions. By eliminating the need for transporting materials between different vendors, in-house manufacturing simplifies logistics, reduces fuel consumption, and improves overall efficiency. Companies like Custprint exemplify this approach by integrating their production processes to minimise waste and streamline quality control.

Additionally, this setup enables quicker turnaround times, leading to more efficient shipping routes and less warehouse handling, which further reduces the environmental impact.

Schedule Production in Batches

Batch scheduling is a smart way to improve energy efficiency and reduce per-item carbon emissions. By grouping similar orders - such as those requiring the same ink colours - you can optimise resource use and minimise equipment cleaning cycles. This not only cuts down on water and chemical waste but also reduces energy consumption tied to frequent start-ups and shutdowns ^[16].

The batching process typically includes key steps like analysing jobs, forming batches, allocating resources, sequencing tasks, and continuously monitoring progress. Efficient resource allocation ensures that machines operate in longer, energy-efficient cycles, which lowers overall costs and environmental impact.

Energy-efficient scheduling (EES) can further enhance this process by aligning production with off-peak energy hours, reducing the carbon footprint even more ^[17]. Regular feedback and monitoring are essential to refine these methods and maximise their effectiveness.

sbb-itb-410132b

Reduce Energy and Resource Usage

Manufacturing processes often demand substantial energy and water, but adopting smarter practices can cut both consumption and costs. By making informed choices, you can reduce your carbon footprint while saving on operational expenses.

Install Energy-Efficient Equipment

Upgrading to modern, energy-efficient machinery can transform your production process. These machines use less electricity while maintaining high productivity levels. For instance, advanced sewing machines, dyeing equipment, and cutting systems are designed to work efficiently, consuming minimal energy without sacrificing speed or quality ^[18].

A great example comes from Crystal International Group in Hong Kong. They upgraded their dyeing machines and achieved a 30% reduction in water and energy use per production cycle ^[18]. This not only reduced their environmental impact but also trimmed operational costs.

Even small changes make a difference. Swapping out traditional lighting for energy-efficient LED lights is a simple yet effective way to cut energy use ^[18]. When considering equipment upgrades, prioritise features like automatic shut-off modes, variable speed controls, and optimised heating systems. These features keep energy consumption low while maintaining consistent performance. Pair these upgrades with renewable energy sources to further enhance efficiency.

Switch to Renewable Energy

India’s renewable energy sector is growing rapidly, offering manufacturers a chance to embrace cleaner energy. The country has ambitious goals, including 500 GW of non-fossil energy capacity by 2030 and achieving net-zero emissions by 2070 ^[19]. As of November 2024, non-fossil fuel capacity in India stands at over 205.52 GW, which is 42% of its total energy capacity ^[20]. Solar energy has seen remarkable growth, with 94.16 GW of installed capacity, while wind energy reached 47.95 GW, more than doubling since 2014 ^[20].

To make the switch, start with an energy audit to identify inefficiencies and areas for improvement. A phased approach works best - begin by sourcing part of your electricity from renewables and gradually increase this share over time. Installing solar panels on factory rooftops is an excellent step. For example, a steel manufacturing plant in Ohio, USA, saved ₹16.6 crore annually on electricity bills after installing solar panels, recouping its investment within five years ^[21].

"We're positioned to harness the opportunities of the energy transition, tapping on our wide distribution network. As an early adopter of renewable energy, we've repositioned our business to address the energy needs of the future, and in doing so, aim to make a difference by delivering a power mix that consists of more renewables, while supporting industries as they make the energy transition." - Raghav Raj Kanoria, Managing Director, India Power ^[22]

Collaborating with renewable energy providers can simplify this transition, offering customised solutions and expert guidance. Smart energy management systems also help maximise the efficiency of your renewable energy investments, cutting emissions and aligning your production with sustainable practices.

Implement Water Conservation Methods

Efficient water usage is another critical aspect of sustainable manufacturing. Processes like cleaning, dyeing, and post-processing can consume vast amounts of water, but recycling systems can significantly reduce this demand. By treating and reusing water multiple times, manufacturers can lower both consumption and wastewater discharge.

Closed-loop water systems are particularly effective. These systems continuously filter and reuse water during dyeing and washing, drastically reducing the need for fresh water. Incorporating water flow monitors and automatic shut-off valves helps identify and address inefficiencies promptly. Additionally, training employees on water-saving techniques fosters a culture of responsibility.

Rainwater harvesting is another smart solution. By capturing and storing rainwater during the monsoon, you can supplement your water supply and reduce dependence on external sources.

Integrating energy-efficient equipment, renewable energy, and water conservation measures creates a well-rounded approach to reducing your carbon footprint. While these investments require upfront costs, they often pay for themselves through lower utility bills and reduced environmental impact.

Minimise Waste and Recycle Materials

Reducing waste goes hand in hand with improving production efficiency, offering a direct way to cut carbon emissions. Waste in production not only contributes to emissions during disposal but also demands extra resources to replace discarded materials. In the fashion industry alone, over ₹7.5 trillion in material value is lost annually, with less than 1% of clothing materials being recycled into new garments ^[25]. In the United States, 85% of textiles end up in landfills or are incinerated ^[26]. For India's growing custom apparel sector, tackling this waste problem is essential for reducing emissions and creating more environmentally conscious operations.

Reduce Textile and Ink Waste

Better design and cutting practices can significantly reduce material waste. Techniques like laser cutting and digital patterning help maximise fabric usage by creating precise patterns that fit together efficiently, leaving minimal offcuts ^[23]. These methods ensure fabric is utilised to its fullest potential.

For scraps that are unavoidable, repurposing them into products like headbands, patches, or other accessories can give them a second life ^[23]. This not only reduces waste but also creates additional revenue streams while cutting down on disposal costs.

When it comes to printing, digital printing technologies are a game-changer. Unlike traditional screen printing, which generates setup waste, digital printing uses only the exact amount of ink required for each design, minimising waste. Beyond production, converting leftover fabric scraps and packaging waste into reusable resources further curbs environmental impact.

Recycle Fabric Scraps and Packaging

The textile recycling industry is evolving, presenting new opportunities for waste management. Mechanical recycling breaks down textiles into fibres, often resulting in lower-quality materials. Meanwhile, chemical recycling, though not yet widely accessible, uses chemical processes to break polymers down into materials that can match the quality of virgin textiles ^[26]. Mechanical recycling, however, remains a practical solution for custom apparel manufacturers today.

An exciting development in textile recycling comes from researchers at Graz University of Technology. In April 2025, Thomas Harter's team unveiled a method to turn discarded clothing into stronger packaging paper. This process involves shredding old clothing, soaking it in a water-based solution, and milling it to separate cotton fibres. These fibres are then blended with recycled paper pulp and processed into durable, recyclable paper suitable for packaging and cardboard.

"Strictly speaking, the conversion of textile fibers into paper is a downgrade, However, it has a major advantage from an environmental point of view. The paper cycle is highly closed, with recycling rates of over 90 percent in the packaging sector." - Thomas Harter, Researcher, Graz University of Technology ^[27]

For packaging, sustainable alternatives like biodegradable materials or recyclable options such as recycled paper and plant-based plastics are gaining traction ^[23]. Minimalist packaging designs reduce reliance on harmful plastics and non-renewable materials, aligning with growing consumer demand for eco-friendly practices ^[24]. Plant-based plastics made from corn or sugarcane are emerging as viable options, and reusable packaging that customers can repurpose is also becoming popular ^[24].

While implementing waste reduction and recycling programmes may require upfront investment, the long-term rewards are undeniable. These efforts not only lower operational costs but also position your custom apparel business as a leader in environmentally responsible practices, complementing energy efficiency and production improvements already in place.

Conclusion

Cutting down carbon emissions in custom apparel isn't just about improving operations; it’s also about enhancing your brand's standing. The fashion industry contributes a staggering 1.2 billion tonnes of carbon emissions annually, even surpassing the aviation sector ^[29]. By adopting sustainable materials and methods, as discussed earlier, businesses can play a key role in reshaping this industry into a more environmentally conscious one.

For Indian businesses, the opportunity is clear. Consider this: between 2003 and 2018, clothing utilisation dropped by 36% ^[29], and a mere 1% of fibres in new apparel come from recycled textiles ^[28]. These numbers highlight the immense potential for improvement. India, with its robust manufacturing base and rising consumer awareness about sustainability, is uniquely positioned to lead this shift. As proof of the growing demand, over two-thirds of UK consumers now prioritise sustainable products ^[30], and Indian shoppers are increasingly following suit.

Adopting sustainable practices doesn’t just benefit the planet - it makes good business sense. Reduced waste, lower energy usage, and improved operational efficiency can all lead to cost savings. At the same time, these efforts appeal to environmentally conscious consumers who actively seek out brands that prioritise responsible production.

"The good news is that it's not too late to build a more circular, more sustainable fashion sector", – Elisa Tonda, Chief of the Resources and Markets Branch, UNEP ^[28].

For businesses ready to take the plunge, the journey begins with small, impactful steps. Start by using low-impact materials and energy-efficient printing techniques. Gradually, expand these efforts to include comprehensive waste management systems and renewable energy solutions. Each of these steps not only reduces your environmental impact but also strengthens your position in an increasingly eco-aware market.

Creating a sustainable custom apparel industry demands collective effort. From choosing eco-friendly materials to implementing better waste management practices, these actions can significantly reduce the 300,000 tonnes of clothing that end up in landfills every year ^[29].

"Consumers have a tremendous amount of power and by choosing more circular options, they can send a signal to those with the influence and means to make the fashion industry more sustainable", – Elisa Tonda ^[28].

The path forward for custom apparel lies in sustainable innovation. By acting now, businesses can lower their carbon footprint, reduce costs, and build a reputation that resonates in a market increasingly focused on eco-friendly solutions.

FAQs

What are the advantages of using locally sourced textiles in India for custom apparel?

Using textiles sourced locally in India for custom apparel production comes with a host of benefits. For starters, it cuts down on carbon emissions by reducing the need for long-distance transportation - an approach that aligns with eco-friendly practices. Beyond the environmental aspect, it bolsters the local economy by creating jobs and supporting small-scale industries. Plus, it often leads to faster production timelines and better quality control.

India's textile heritage is a treasure trove, offering premium fabrics like Suvin and Kasturi cotton, both celebrated for their superior quality and eco-conscious production. Opting for these local materials allows businesses and individuals to craft clothing that’s not only environmentally responsible but also deeply connected to India’s cultural roots.

What makes direct-to-garment (DTG) printing more eco-friendly compared to traditional screen printing?

Direct-to-garment (DTG) printing stands out as a more environmentally friendly alternative to traditional screen printing for several reasons. For starters, DTG uses water-based inks, which are gentler on the environment and produce very little chemical waste. Plus, its print-on-demand model ensures that only the required items are printed, cutting down on overproduction and unnecessary material waste.

On the other hand, traditional screen printing often relies on solvent-based inks that release volatile organic compounds (VOCs), which contribute to air pollution. This method also demands more energy and generates significant waste due to its setup process and the need to maintain excess inventory. By limiting chemical use, reducing waste, and being more energy-efficient, DTG printing offers a cleaner, more environmentally conscious way to produce custom apparel.

How can custom apparel businesses effectively adopt renewable energy solutions?

Custom apparel businesses can take meaningful steps towards using cleaner energy. Installing solar panels or wind turbines on-site is a great way to generate renewable energy directly, cutting down reliance on fossil fuels. Alternatively, they can purchase renewable energy from certified providers or adopt energy management systems to make power usage more efficient. These measures not only help reduce carbon emissions but also make operations more environmentally friendly and cost-effective.