CARBON FOOTPRINT ASSESSMENT IN TEXTILE WET PROCESSING INDUSTRIES

Vijay Shirole – Senior Scientific Officer – I

The Bombay Textile Research Association, Mumbai

Abstract

The concept of carbon footprint is pivotal in understanding and mitigating the environmental impacts of human activities. As the global focus shifts toward sustainable development, the need for comprehensive carbon footprint assessments has become increasingly significant, especially for industries that have large-scale environmental impacts. This paper explores the methodologies, processes, and tools for assessing and calculating the carbon footprint, with a special focus on industry-specific applications. The importance of carbon footprint measurement in reducing greenhouse gas (GHG) emissions is discussed, and the paper examines various approaches to calculating carbon emissions from direct and indirect activities. By providing a structured framework for carbon footprint assessment, this paper aims to guide industries, policymakers, and individuals toward more informed decisions in the fight against climate change.

Keywords:

Carbon footprint, textile industry, wet processing, sustainability, lifecycle analysis, energy efficiency, chemical management, carbon reduction.

1. Introduction

The carbon footprint, which represents the total amount of greenhouse gases (GHGs) emitted by human activities, has become a key metric in the context of climate change mitigation. These emissions contribute directly to global warming and climate change, which threaten ecosystems, economies, and human health. 

The carbon footprint of textile wet processing industries refers to the total amount of greenhouse gases (GHGs) emitted as a result of various activities contributing to carbon emissions during textile wet processing, including energy consumption, water heating, chemical reactions, and waste disposal.

• Energy Use (electricity, steam, fuel)
• Water and Chemical Inputs (dyes, surfactants, etc.)
• Emissions from Dyeing and Finishing
• Transportation and Supply Chain Emissions

These processes are highly energy-intensive and often involve substantial water and chemical use, making it crucial to calculate the associated carbon emissions in order to identify opportunities for reductions and improve sustainability.

Textile industry and its contribution to CO2 emissions:

The textile industry, according to the U.S. Energy Information Administration, is the 5th largest contributor to CO2 emissions. Thus, the textile industry is huge and is one of the largest sources of greenhouse gasses on Earth. In 2008, annual global textile production was estimated at 60 bn kg of fabric. The estimated energy and water needed to produce such quantity of fabric is considered to be

• 1,074 bn kWh of electricity or 132 mn MT of coal and
• About 6-9 tn liters of water

 Thus, the thermal energy required per meter of cloth is 4,500-5,500 Kcal and the electrical energy required per meter of cloth is 0.45-0.55 kwh

2. The Importance of Carbon Footprint Assessment

A carbon footprint assessment involves the quantification of greenhouse gas emissions directly and indirectly caused by an individual, organization, event, or product. It enables stakeholders—governments, corporations, and consumers—to:

• Quantify Environmental Impact: By understanding the total GHG emissions from an activity or organization, stakeholders can gauge the environmental consequences and focus on the largest sources of emissions.
• Support Decision-Making: Accurate carbon footprint data can help organizations and governments make informed decisions on resource allocation, sustainability investments, and carbon mitigation strategies.
• Identify Hotspots for Emission Reductions: Carbon footprint assessments can highlight areas where the greatest emissions occur (e.g., energy use, transportation, waste) and guide strategies to reduce these emissions.
• Regulatory Compliance: Many countries and regions are now mandating emissions reporting, including carbon footprint calculations, as part of environmental laws. Accurate assessments help organizations comply with regulations and contribute to national and international GHG reduction targets.
• Improve Transparency and Accountability: By measuring and reporting carbon footprints, organizations can demonstrate environmental responsibility, which can enhance their brand image and strengthen consumer trust.
• Enable Carbon Offsetting: Accurate assessments allow organizations to identify emissions that cannot be eliminated and offset them through carbon credits or projects aimed at reducing global emissions.

3. Key Concepts in Carbon Footprint Calculation

A carbon footprint is typically calculated based on the amount of greenhouse gas emissions (GHGs), expressed in carbon dioxide equivalents (CO₂e), from a specific activity or product. The major GHGs include:

• Carbon Dioxide (CO₂): The most common greenhouse gas, emitted primarily from the burning of fossil fuels.
• Methane (CH₄): A potent greenhouse gas emitted from agriculture, waste management, and energy production.
• Nitrous Oxide (N₂O): Emitted from agricultural practices, industrial processes, and the use of fertilizers.
• Fluorinated Gases: A group of synthetic greenhouse gases used in industrial applications such as refrigeration and air conditioning.

These gases have different global warming potentials (GWPs). CO₂e is used to standardize the impact of all gases, making it easier to compare and aggregate emissions.

4. Methodology for Carbon Footprint Calculation

To calculate the carbon footprint of textile wet processing, we can break down the process into several components and estimate emissions based on key factors such as energy consumption, water use, and chemical inputs. The most widely used methodology is Life Cycle Assessment (LCA), which quantifies the environmental impacts (including carbon footprint) of each stage in the textile production lifecycle.

The Carbon Footprint is assessed in 2 layers; 

1. Primary footprint – monitors carbon emission directly through energy consumption – burning fossil fuels for electricity, heating and transportation, etc. 
2. Secondary footprint– relates to indirect carbon emissions (Life cycle of products and Sustainability). Thus, the most effective way to decrease a carbon footprint is to either decrease the amount of energy needed for production or to decrease the dependence on carbon emitting fuels

The calculation process generally involves quantifying direct emissions (e.g., from energy use) and indirect emissions (e.g., from the production of chemicals or from transportation). The following steps outline the methodology and approach for calculating the carbon footprint for textile wet processing.

5. Key Steps in Carbon Footprint Calculation:

1. Identify Boundaries: Determine the scope of the study (cradle-to-gate, cradle-to-cradle, or cradle-to-grave). For wet processing, it typically covers the stages from fabric preparation (e.g., dyeing, bleaching) to the final product leaving the factory.
2. Data Collection: Collect data on:
   • Energy Consumption (electricity, steam, fuel) used in wet processing operations.
   • Water Use for dyeing, washing, and finishing processes.
   • Chemicals and Auxiliary Inputs used in dyeing, bleaching, finishing, and printing.
   • Wastewater and Chemical Waste generated during the processes.
   • Transportation and Logistics (for materials, chemicals, etc.).
3. Emission Factors: Apply emission factors to convert the inputs (energy, water, chemicals) into CO₂-equivalent (CO₂e) emissions. Emission factors are available in databases such as those provided by the Intergovernmental Panel on Climate Change (IPCC), EPA, and Eco invent.
4. Calculate Direct and Indirect Emissions:
   • Direct Emissions: These include emissions from energy consumption, fuel use, and process-related emissions (e.g., CO₂ released from burning natural gas for steam generation).
   • Indirect Emissions: These emissions result from the supply chain, such as those associated with the production and transportation of chemicals, dyes, or raw materials.
5. Summing Up Emissions: Aggregate the emissions from all stages of textile wet processing to obtain the total carbon footprint.

6. Strategies for Reducing Carbon Footprint in Textile Wet Processing

• Cleaner Production Technologies: Identification of clean technologies that reduce energy consumption, chemical use, and waste generation.
• Eco-labelling and Certification: Overview of environmental certifications and standards such as GOTS (Global Organic Textile Standard), OEKO-TEX, and ISO 14001, and their role in driving sustainable practices.
• Circular Economy in Textiles: Exploration of the potential of circular economy principles, such as recycling and reusing textile waste, in reducing the carbon footprint of textile production.
• Shift Toward Sustainable Fabrics: Discussion on the use of sustainable materials, including organic cotton, hemp, and recycled fibres, as a means to reduce environmental impacts.
• Energy Efficiency: Implementing energy-efficient technologies and practices can significantly reduce emissions.
• Renewable Energy: Transitioning to renewable energy sources (e.g., solar, wind, hydro) can reduce emissions from electricity use.
• Sustainable Transportation: Shifting to electric vehicles (EVs), improving logistics, and reducing travel distances can cut down emissions from transportation.
• Circular Economy: Reducing, reusing, and recycling materials can reduce the carbon footprint in the product lifecycle.

7. Conclusion

The carbon footprint calculation for textile wet processing involves estimating emissions from key activities like energy use, water treatment, chemical consumption, and waste management. By applying emission factors to these activities, companies can calculate the total carbon footprint of their processes. These calculations are crucial for identifying areas where energy efficiency, chemical use, and water consumption can be optimized to reduce the environmental impact of textile production. Through such assessments, textile industries can work toward more sustainable practices and meet global environmental standards. If the facility wants to assess the carbon footprint, BTRA team is ready to assist the same.

References

1. Comprehensive list of scholarly articles, industry reports, and other relevant sources used in the paper.
2. Allwood, J. M., et al. (2006). “The Environmental Impacts of the Textile Industry.” Cambridge University Press.
3. Kering (2020). “Environmental Profit & Loss: Textile Footprint Report.”
4. Global Fashion Agenda (2021). “Circular Fashion: The Apparel Industry’s New Agenda.”
5. ISO 14040:2006, “Environmental Management—Life Cycle Assessment—Principles and Framework.”
6. Sharma, P., et al. (2020). “Energy and Water Management in Textile Wet Processing.” Journal of Cleaner Production, 123, 142-158.