At the heart of the environmental sustainability debate, water stands out as one of the planet’s most precious—and most threatened—resources. The textile industry, a global economic powerhouse and ever-evolving sector, is unfortunately known for its intensive resource use, with a significant environmental footprint. From the cultivation of natural fibers to complex dyeing and finishing stages, every production phase requires large quantities of water. This reality raises urgent concerns about current practices and calls for innovative solutions to build a more responsible future.

The water footprint of the textile sector: facts and impacts

Water consumption in the textile industry is staggering. The fashion industry alone consumes an astounding 1.5 trillion liters of water annually, as highlighted by the European Parliament. A large portion of this consumption stems from the cultivation of natural fibers—cotton being one of the most water-intensive crops both historically and today.

This issue is far from new. As early as the 2000s, multiple studies began analyzing the water footprint of textile production. One key study on the water footprint of global cotton product consumption, covering 1997–2001, found that global cotton consumption required 256 billion cubic meters (Gm³) of water per year. Of this, approximately 42% was blue water (direct freshwater withdrawal for irrigation), 39% was green water (rainwater) and 19% was grey water (used to dilute pollutants). For the EU25 region, about 84% of this water footprint was external—originating in countries like India and Uzbekistan, where water resources were already under significant stress (source: Hoekstra & Chapagain, 2006).

More recently, the "Water Footprint in Cotton 2020–2024: A Global Analysis" report by the International Cotton Advisory Committee (ICAC), based on data from 38 countries, has provided updated insights. Even with modern methodologies, the numbers remain significant: producing one kilogram of cotton fiber requires an average of 8,920 liters of water globally. While most of this comes from rainfall (about 6,576 liters/kg or 73.4%), the remaining 2,344 liters/kg (26.6%) represent direct freshwater extraction—still a considerable draw on already-stressed aquifers and rivers. These distinctions matter for in-depth analysis but don’t change the reality: water consumption in cotton textile production remains extremely high.

To put it in perspective, producing a single cotton T-shirt can require around 2,700 liters of water—equivalent to what a person drinks in 2.5 years—while a pair of jeans may demand up to 10,000 liters.

It's not just fiber cultivation that drives high water use. Industrial processes like dyeing and finishing are also major contributors. The dyeing process alone consumes around half a trillion gallons (approx. 1.9 trillion liters) of freshwater annually. The fashion industry is estimated to be responsible for roughly 20% of global industrial water pollution. The widespread use of chemicals and water often results in untreated industrial wastewater being discharged into rivers and groundwater, causing serious harm to ecosystems and local communities.

The need for alternatives: reducing water use in textile production

Given these alarming figures, the textile industry is in urgent need of transformation. Reducing water consumption is no longer optional—it is essential for environmental sustainability and the industry's long-term resilience. This means rethinking the entire supply chain, adopting more efficient and innovative practices, and investing in low-impact yarns.

Key strategies include:

Process innovation: adopting low-water or waterless dyeing technologies, implementing water recycling and reuse systems within production facilities, and improving machinery efficiency.
Low-impact fibers: promoting and developing fibers that require less water to produce, supported by trusted textile certifications that verify sustainability.
Circular economy models: encouraging textile recycling at end-of-life to reduce the need for virgin fiber production and associated water usage.

Innovative yarns: Fulgar’s solutions for responsible water use

Fulgar is at the forefront of research and development in yarns that offer concrete solutions to the textile industry's water consumption problem. The company is committed to delivering alternatives that combine top performance with drastically reduced environmental impact.

Among Fulgar’s most notable innovations:

Recycled Yarns: Fulgar produces yarns from recycled raw materials. A flagship example is Q-CYCLE® yarn, a polyamide derived through an innovative chemical recycling process that repurposes end-of-life tire waste. This cutting-edge method transforms otherwise discarded materials into valuable resources. Using recycled raw materials significantly reduces the need for virgin resources, including water. For instance, recycled nylon production can cut water consumption by up to 90% compared to conventional nylon, based on LCA (Life Cycle Assessment) studies.
Bio-Based yarns: yarns like EVO® by Fulgar, which are 100% bio-based and derived from castor oil and industrial corn, represent a breakthrough in reducing the water footprint. Both feedstocks are fully renewable, require minimal water, and do not compete with food crops for arable land. This results in drastically lower water usage compared to traditional natural or synthetic fibers.
Efficient production processes: Fulgar also focuses on optimizing its own manufacturing operations. The company invests in advanced technologies to minimize water consumption and ensure proper treatment of wastewater, supporting a more conscious use of natural resources.

Toward a water-smart textile future

Water consumption in the textile industry presents a complex challenge requiring collective action across the entire supply chain. Choosing innovative yarns and responsible production processes is the first step toward a future where the textile industry can thrive without depleting the planet’s vital water reserves. Fulgar is proud to be part of this transformation—offering solutions that enable brands and manufacturers to create high-quality products with a smaller environmental footprint, supporting a more mindful use of our natural resources.

Interested in learning how Fulgar can help you integrate low-water-impact yarns into your projects? Get in touch with us for a personalized consultation.