Quantitative Assessment of Cost Implications for Sustainability in the Knitwear Industry

Abstract

Sustainable textile production aims to reduce environmental impact, yet the financial trade-offs remain a critical concern for manufacturers. This study provides a quantitative assessment of the cost implications of implementing sustainability measures in the fabric finishing department of a knitwear industry. Three finishing setups were analyzed – conventional, intermediate, and fully sustainable – focusing on resource consumption (water and chemicals) and production costs for a standard 180 gsm cotton knit polo shirt. Data were collected via detailed industrial surveys on process-wise water use, chemical inputs, and cost breakdowns. The sustainable finishing unit achieved drastic reductions in water usage (~24 L/kg vs. 46 L/kg in conventional processing) and chemical consumption (e.g. eliminating enzyme use and cutting hazardous chemicals by ~30–50%), thereby minimizing environmental footprints. However, these gains came with higher production costs: the sustainable process incurred the highest fabric and garment cost per unit, roughly 2–3× the conventional cost. The intermediate scenario showed moderate improvements in resource efficiency with milder cost increase. Despite greater upfront costs, sustainable practices yielded long-term benefits in compliance, brand value, and product quality, and commanded a premium price that offset some costs. The results underscore that investing in cleaner production technologies and eco-friendly processes can be economically viable when considering lifecycle benefits and evolving market/regulatory pressures. This comprehensive cost-benefit analysis offers critical insights for textile manufacturers and policymakers seeking to balance sustainability goals with economic performance in the pursuit of a more sustainable fashion industry.