How Textile and Apparel Waste Produced in Manufacturing Factory?

Waste Management in Apparel Industry:
The apparel business is becoming more competitive and the customers expect higher quality for fewer prices. To survive and perform in this business scenario, manufacturing companies have to reduce the costs through different ways. It should be noted here that, one of the largest costs involved in most of the manufacturing operations is wastage which is unavoidable. 

Wastage or waste formation in textile and apparel industry
Fig: Wastage or waste formation in textile and apparel industry
Particularly in the apparel manufacturing industry, the wastage percentage is high due to integrated process sequence and also the interaction the men and machine is more which is also leads to the certain percentage increase in wastage.

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Causes of Wastage or Waste Formation in Textile and Apparel Industry:
The forms of textile and apparel waste or wastage are as follows:
  1. Left over raw materials,
  2. Scraps from production,
  3. Rejections,
  4. Trial run quantity,
  5. Waste from poor material handling.
All the above wastage or wastes have explained in the below:


1. Left over raw materials:

This form of wastage is due to the input raw materials which are left unused in the input area at the end of production process. For example, left over yarn in the yarn cones and creels tunes in the textile knitting, warping etc.

2. Scraps from production:

This type of wastage arises during the manufacturing process due to machine breakdown, cutting, shaping or finishing etc. and which cannot be reused for the manufacturing. For example, fabric wastes from the fabric cutting operation or process.


3. Rejections:
Rejections are the production units that do not meet the product specifications or standard approved by the buyer due to defects or faults, poor workmanship etc. In clothing manufacturing industry; it is normally sold at reduced prices.

4. Trial run quantity:

In some processes, before going in for the bulk production, a trial run or test run has to be carried out to bring the standard operating or process condition. This quantity of the material cannot be used further anymore. For example, trial runs printing, finishing etc.

5. Waste from poor material handling:

This types of wastage arises due to poor material handling during the wet processing stages, buttons and label are lost during the sewing operation because of poor handling etc.