What is Consumption in the Garment Industry?

Consumption in the garment industry refers to the amount of fabric, trims, and accessories required to manufacture a specific garment. Accurate consumption calculation is crucial for cost estimation, material procurement, and waste reduction. It ensures the efficient use of resources while maintaining profitability.

Importance of Consumption Calculation in the Garment Industry

1. Cost Estimation – Proper consumption calculation helps manufacturers determine the exact cost of raw materials, ensuring competitive pricing and profitability. Proper consumption calculation helps determine the cost of raw materials, impacting the overall price of the garment.
2. Fabric Utilization – Optimizing fabric consumption reduces wastage, leading to more sustainable production and cost savings. Minimizing fabric wastage is essential for sustainability and cost savings.
3. Production Planning – Knowing precise material requirements allows manufacturers to streamline production, avoiding delays and inefficiencies. Manufacturers can plan production effectively by knowing the exact material requirements.
4. Inventory Management – Helps in avoiding excess or insufficient stock of materials. Helps maintain optimal stock levels, preventing overstocking or shortages that could disrupt production schedules.
5. Profitability – By minimizing waste and optimizing resource use, manufacturers can reduce production costs and enhance profitability. Accurate consumption ensures correct pricing, maximizing profit margins.
6. Sustainability & Eco-Friendly Practices – Accurate consumption calculation supports environmentally friendly manufacturing by reducing excess material usage and promoting sustainable sourcing.

Types of Consumption in Apparel Manufacturing

In apparel manufacturing, consumption refers to the amount of fabric, trims, and accessories required to produce a garment. It is an essential factor in cost estimation, production planning, and inventory management. There are different types of consumption calculations in apparel manufacturing:

1. Fabric Consumption – The amount of fabric required for a garment, calculated based on pattern pieces and wastage. Fabric is the most significant cost component in garment production. Fabric consumption is calculated based on pattern measurements, fabric width, and wastage. It can be categorized as: Includes fabric wastage due to cutting loss, shrinkage, and defects. Excludes fabric wastage and considers only the fabric used for the actual garment.
2. Trims Consumption – Includes buttons, zippers, labels, and other accessories needed for garment construction. Trims include zippers, buttons, labels, elastic, interlining, and other accessories. Trim consumption is measured in: Piece-Based (e.g., buttons, zippers, labels), Length-Based (e.g., elastic, tape, drawstring), Weight-Based (e.g., fusible interlining, lace, foam padding)
3. Thread Consumption – The length of thread required for stitching different types of garments. Thread consumption depends on the type of stitch, seam length, and fabric thickness. It is calculated as:
4. Lockstitch Consumption – Typically, 1.5 to 2.5 times the seam length.
5. Overlock Consumption – Usually 3 to 5 times the seam length.
6. Coverstitch Consumption – Generally higher than lockstitch and overlock due to multiple threads.
7. Packaging Consumption – Materials used for packaging, such as poly bags, tags, and boxes.
8. Dye & Chemical Consumption – Used in fabric processing and finishing stages.
9. Lining and Interlining Consumption: Lining is used in jackets, coats, and suits to improve comfort and durability. Interlining is used for reinforcement in collars, cuffs, and waistbands. The consumption is based on pattern requirements.
10. Packaging Consumption: Packaging materials include polybags, cartons, hangers, tags, and barcode stickers. Their consumption is determined by: Garment Folding Method, Carton Packing Size, Brand & Retailer Requirements,
11. Washing & Finishing Consumption: For garments requiring special washes (e.g., enzyme wash, stone wash, bleach wash), additional water, chemicals, and energy consumption are considered.
12. Label & Tag Consumption: Labels and tags (brand labels, care labels, price tags) are calculated per garment based on buyer specifications.

How to Calculate Fabric Consumption?

Fabric consumption is the most critical aspect of cost estimation in garment production. Proper calculation helps optimize material usage, reduce waste, and control costs.

Fabric consumption can be calculated using:

• Marker Planning Method – Using CAD software or manual layout to optimize fabric use.
• Average Fabric Consumption – Based on previous production data for similar garments.
• Pattern-based Calculation – Measuring the dimensions of pattern pieces with added allowances.

Steps1:

1. Measure the Length & Width of Each Component:
   • Example: Front panel = 70 cm × 50 cm, Back panel = 75 cm × 50 cm.
2. Calculate the Area of Each Component (if fabric is non-standard shape):
   • Area of Front panel = 70×50=3500 cm2
3. Convert to Fabric Length (For Width-Fixed Fabric Rolls):
   • Fabric width = 150 cm
   • Total Area = 3500+3750=7250 cm2
4. Fabric Length Required = 7250/150=48.33cm (0.48 meters per garment)

Steps2:

1. Create a Marker Plan: Lay out patterns for a specific fabric width.
2. Determine the Fabric Length Needed for One Marker:
   • Example: A marker for 10 garments requires 5 meters of fabric.
3. Calculate Fabric per Garment:
   • Fabric per garment = 5/10=0.5 meters.

Types of Fabric Consumption

• Net Fabric Consumption (Only pattern area)
• Gross Fabric Consumption (Includes cutting loss, shrinkage, defects)

Wastage Considerations

Fabric wastage is an unavoidable factor in apparel manufacturing and must be included in fabric consumption calculations to ensure accurate cost estimation. Different types of wastage occur at various stages of production.

Occurs during fabric cutting due to the shape of pattern pieces and the arrangement on the fabric roll.
✅ Factors Influencing Cutting Waste:

• Fabric width efficiency
• Marker planning (manual vs. CAD-based)
• Pattern shape complexity
  🔹 Typical Waste Percentage:
• Woven Fabric: 3-5%
• Knitted Fabric: 5-10%
• Shrinkage Waste: Fabric shrinks during pre-wash or finishing, leading to extra fabric usage.
• ✅ Causes: Natural fiber shrinkage (cotton, linen), Heat treatment during washing or ironing
  🔹 Typical Shrinkage Allowance: 2-5% (depends on fabric type)
• Defective Fabric Waste: Fabric defects like holes, stains, and misprints lead to unusable fabric portions.
• ✅ Minimization Methods: Fabric inspection before cutting (4-point system) Reusing defective areas for non-visible garment parts
  🔹 Typical Waste Percentage: 1-3%
• Stitching & Seam Allowance Waste: Some extra fabric is required for seam allowance, pleats, gathers, and adjustments during stitching.
• 🔹 Typical Waste Percentage: 2-4%
• Selvage Waste: Edges of woven fabrics (selvage) are not usable in garments.
• 🔹 Typical Waste Percentage: 1-2%
• Total Fabric Wastage Consideration
  When calculating gross fabric consumption, the total wastage should be added as a percentage of net consumption.
  🔹 General Wastage Allowance Guidelines:
  Woven Fabric:6-10%
  Knitted Fabric:8-15%
  Denim Fabric:12-18%

Best Practices for Optimizing Consumption in the Garment Industry

Efficient fabric consumption is essential for cost reduction, sustainability, and improving profit margins in apparel manufacturing. Below are the best practices for optimizing fabric and material usage in the garment industry.

Best Practices for Optimizing Fabric Consumption in the Garment Industry

Efficient fabric consumption is essential for cost reduction, sustainability, and improving profit margins in apparel manufacturing. Below are the best practices for optimizing fabric and material usage in the garment industry.

1. Efficient Marker Planning

📌 What is Marker Planning?

Marker planning involves arranging garment pattern pieces on fabric to minimize wastage.

✅ Best Practices:

• Use CAD-based marker making (Gerber, Lectra, Optitex) for better accuracy.
• Arrange patterns tightly and strategically to reduce gaps.
• Use multi-size markers when producing different sizes in bulk.
• Reduce selvage waste by adjusting patterns closer to the fabric edge.
• Utilize remnant fabric for small parts (pockets, plackets, facings).
• 🔹 Expected Savings: 3-8% fabric reduction

2. Proper Fabric Width Selection

📌 Why does it matter?
Fabric width affects how efficiently patterns are placed.

✅ Best Practices:

• Choose a fabric width that best suits garment patterns to reduce cutting waste.
• Avoid excessive width that leads to higher wastage in marker planning.
• Use narrow-width fabric for smaller garments to reduce excess fabric waste.

🔹 Expected Savings: 2-5% reduction in fabric waste

3. Reduce Cutting Waste

📌 Why is it important?
Poor cutting techniques can result in excessive fabric loss.

✅ Best Practices:

• Use automatic cutting machines (laser, die-cut, or computerized cutters) for precision.
• Train workers to cut close to marker lines without unnecessary margins.
• Reuse offcuts for sample production or smaller components.
• Implement fabric layering techniques to improve efficiency.

🔹 Expected Savings: 3-6% fabric reduction

4. Manage Shrinkage Allowances Efficiently

📌 Why does shrinkage matter?
Some fabrics shrink after washing, requiring additional fabric allocation.

✅ Best Practices:

• Pre-shrink fabric before cutting to avoid unexpected size variations.
• Use fabric with stable shrinkage rates when possible.
• Apply accurate shrinkage factors (e.g., 3% for cotton, 2% for synthetic) in fabric calculations.

🔹 Expected Savings: 2-4% fabric reduction

5. Optimize Fabric Inspection & Quality Control

📌 Why is this important?
Fabric defects lead to additional fabric wastage.

✅ Best Practices:

• Implement the 4-Point Fabric Inspection System to detect defects early.
• Sort and separate defective fabric to use in non-visible areas of garments.
• Work with suppliers to ensure consistent fabric quality and minimize rejects.

🔹 Expected Savings: 1-3% fabric reduction

6. Implement Lean Manufacturing Principles

📌 What is Lean Manufacturing?
A production method that reduces waste, improves efficiency, and enhances quality.

✅ Best Practices:

• Reduce waiting time in cutting and sewing to minimize material loss.
• Improve layout planning to reduce unnecessary fabric movement.
• Use real-time monitoring systems to track fabric usage and adjust accordingly.

🔹 Expected Savings: 5-10% improvement in overall material efficiency

7. Utilize Leftover & Scrap Fabric Smartly

📌 Why should you reuse fabric?
Leftover fabric and scraps contribute to waste and increased costs.

✅ Best Practices:

• Use scrap fabric for accessories, trims, or children’s wear.
• Sell fabric remnants to recycling firms for upcycling.
• Implement a zero-waste cutting strategy where possible.

🔹 Expected Savings: 3-7% waste reduction

8. Smart Fabric Storage & Handling

📌 Why does storage matter?
Improper storage can cause fabric damage, leading to avoidable waste.

✅ Best Practices:

• Store fabric in climate-controlled areas to prevent shrinkage and damage.
• Label fabric rolls properly to avoid mixing different shrinkage rates.
• Rotate fabric stock using FIFO (First In, First Out) to use older fabric first.

🔹 Expected Savings: 1-2% waste reduction

Summary of Potential Savings

By implementing these best practices, garment manufacturers can significantly reduce costs, minimize waste, and improve efficiency in fabric usage.

• Quality Control – Ensuring precise cutting and stitching to avoid material loss.
• Lean Manufacturing Techniques – Implementing lean principles to improve resource utilization.
• Technology Adoption – Using CAD software and automated cutting machines for accuracy.

FAQs

1. Why is fabric consumption important in garment costing?
Fabric contributes to a significant portion of garment cost; accurate calculation helps in setting competitive prices.

2. How is thread consumption calculated?
Thread consumption depends on stitch type, seam length, and fabric thickness, usually measured in meters or yards per garment.

3. What factors affect fabric consumption?
Garment design, fabric width, shrinkage, and cutting techniques influence fabric consumption.

4. How can garment manufacturers reduce material wastage?
By using optimized marker planning, precision cutting, and sustainable fabric sourcing, manufacturers can minimize wastage.

Conclusion

Consumption in the garment industry plays a vital role in cost control, efficiency, and sustainability. Proper consumption calculation helps manufacturers optimize resources, reduce waste, and improve profitability. Implementing advanced techniques and technology can further enhance accuracy and operational efficiency.