{"id":17348,"title":"How t-shirts are made","description":"T-shirt production usually works on a linear model: products are made, used, then thrown into landfill. At Teemill, we\u2019ve redesigned the clothing supply chain to be circular, meaning nothing is wasted. Go behind the scenes in this video and blog to find out how your t-shirts are made, how your sustainable manufacturing facilities operate, and how the circular economy model your brand is a part of works to reduce waste, from the fields in India where your organic cotton is grown, to the t-shirt printing factories making your products in the UK. \n\nShare the video with your customers on your site for instantly engaging content or take your favourite bits and share easily to socials, with some behind the scenes photos from Drive.","content":"<blockquote><p><em>99% of clothes aren\u2019t recycled. Welcome to the 1%.<\/em><\/p><\/blockquote><p>T-shirt production works on a linear model where products are made, used, then thrown into landfill, and this leaves us with problems. There is limited space on Earth, and filling it with over 2 billion tons of waste a year doesn't seem to us the best use of the space. Consider the cost of trash on a global scale - not just environmental, but material and financial, too.<\/p><p>A linear supply chain where things are designed to be thrown away reduces resources, turns them into trash and trashes nature at our expense. It doesn\u2019t really make sense. That\u2019s why when we make t-shirts, we make them in a different way.<\/p><p>So, how is cotton clothing made at Teemill? In this post, we'll explain the process. Understanding how sustainable clothing is made means exploring the full supply chain, from growing the cotton to printing your designs on the finished t-shirt.<\/p><h3>\ud83d\udca1\ud83d\ude80 Want to start a sustainable clothing brand?<\/h3><p><strong><a href=\"https:\/\/teemill.com\/sign-up\/brand\" target=\"_blank\" rel=\"noreferrer noopener\">Create your own sustainable clothing for free using Teemill<\/a><\/strong><\/p><iframe src=\"https:\/\/www.youtube.com\/embed\/zCD_bssV4ak\/?modestbranding=1&amp;rel=0&amp;controls=0&amp;showinfo=0&amp;vq=highres\" height=\"350\" frameborder=\"0\" allowfullscreen=\"\"><\/iframe><p>At Teemill, we\u2019ve redesigned the clothing supply chain to be circular, where new products are made from worn out material so instead of creating waste, we just make new products from it. Products are made up of materials, and those materials are valuable, so by saving and reusing material, we can save money. That means we can afford to use natural organic materials, renewable energy and sustainable packaging. It means we save the environment from landfills too. So how does <u><a href=\"https:\/\/teemill.com\/blog\/ted-talk-sustainability-circular-economy\/\" target=\"_blank\" rel=\"noreferrer noopener\">our circular supply chain<\/a><\/u> work?<\/p><p>So much of our thinking is linear, that it\u2019s difficult to tell the story of a circular supply chain. We\u2019re used to stories having a beginning, a middle and an end. In a closed-loop supply chain, <em>there is no end<\/em>. So where should we start? Let's go with materials.<\/p><p><\/p><h2>How cotton is made into clothes<\/h2><h3><img src=\"https:\/\/images.teemill.com\/jv6qfzakgg0tdzpfdfrjmknficqn9ja9yczvvubalhqrb6fp.jpeg.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"95800476\"><br><strong>How is organic cotton made?<\/strong><\/h3><p>All our clothes are made from organic cotton, and they are GOTS certified. You can <a href=\"https:\/\/teemill.com\/traceability\" target=\"_blank\" rel=\"noreferrer noopener\">view all of Teemill's certifications and accreditations here.<\/a><\/p><p><img src=\"https:\/\/images.teemill.com\/ls6poj7q8odhx0y6aiuvcg3ri72txpesz4xgmhgxrtc0jjzy.jpeg.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"\">Cotton has been grown in India since 5000 BCE - and for good reason. It\u2019s natural, durable, absorbent (which means it\u2019s easy to dye), and most importantly, comfortable. We chose to create products made from 100% cotton to make recycling them much easier. Mixed materials bring up all sorts of challenges.<\/p><blockquote><p>By designing our products in this way, paying close attention to the start of the process, we have been able to build circularity into the system, rather than trying to retrofit it later.<\/p><\/blockquote><p>Cotton isn't perfect, though.<\/p><p>One of the largest issues in cotton production is the amount of water it requires to grow - that\u2019s why our organic cotton is grown in the north of India, in Gujarat, where monsoons fill reservoirs that supply the water needed, without irrigation.<\/p><p><img src=\"https:\/\/images.teemill.com\/cryiwkqywpdbhkh94liplt7ttj1a9ssn1fdxio6an3iwrxqf.jpeg.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"\">Organic cotton is grown without the harmful chemicals that are in most pesticides and fertilisers. Instead, our farmers use natural fertilisers like cow poo. Then, when the cotton seeds are separated from the usable part of the fibre (called cotton ginning), those seeds are pressed and used to feed cows, who can then turn it into natural fertiliser! A circle within our circular supply chain.<\/p><p>So, how is cotton made into clothes? Once the cotton has been picked and ginned, it is sent south to the Tamil Nadu region of India.<\/p><p><img src=\"https:\/\/images.teemill.com\/1euce6qkusod3dmafq2omyc8hqpigdvhw98qybcnixajzriv.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"\">There, it is transformed into fabric and eventually into finished products.<\/p><p><img src=\"https:\/\/images.teemill.com\/af6a5o4kdojdqahauilreub9ae3buooduvcnfviznppqhz73.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"\"><img src=\"https:\/\/images.teemill.com\/71pvhvgzr9drjiazu9wbnxvbzslhrqdfiwhfgt9pkjtydonv.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"\">The cotton is checked for impurities and spun into yarn using state-of-the-art machinery. Advanced engineering allows for the yarn to be woven into fabric using automated machines, too. Our partners in Tamil Nadu have some of the largest and most modern spinning facilities in the world. The cotton goes through multiple checks and is tested for purity and strength.<\/p><p><img src=\"https:\/\/images.teemill.com\/qdxebh6ts6jrumda6ystdif4o6eqm58yxqju5wrlvtafgj46.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"\">The fabric is then sent to the dyeing plant, a short distance from the spinning mill. We have a completely closed-loop water recycling system, so that the water used to dye our clothes isn\u2019t released into the local waterways, to pollute the area.<\/p><p>We filter and distil this water, separating it from the dye using osmosis. This is basically like sucking it up through a layer of really fine sand, over and over, then boiling it. Once we add salt into the water, it adheres to all the dye particles, which can then be removed and reused for things like road markings. The water that is left is clean enough to drink - literally:<\/p><iframe src=\"https:\/\/www.youtube.com\/embed\/t2QPs6E8X3Q\/?modestbranding=1&amp;rel=0&amp;controls=0&amp;showinfo=0&amp;vq=highres\" height=\"350\" frameborder=\"0\" allowfullscreen=\"\"><\/iframe><p>After dyeing, the fabric is sent to a similar factory, where large sheets of it are cut and sewn together to create t-shirts and more.<\/p><p><img src=\"https:\/\/images.teemill.com\/trnsjfccqoyzjluxbe4bmevpti7l9gagvy5pzwlnj5safyzu.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"\"><img src=\"https:\/\/images.teemill.com\/oxx0dhvzmzfcockdzqwjapm5fydwxa5apq4d6yxeobw6yhwg.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"\">Finishing touches, labels and details are added to create the final item. These blank products are then boxed up and sent to our factories, ready for printing.<\/p><p><\/p><h3>\ud83d\udca1\ud83d\ude80 Let's create your sustainable products<\/h3><p><strong><a href=\"https:\/\/teemill.com\/sign-up\/brand\" target=\"_blank\" rel=\"noreferrer noopener\">Customise our organic cotton range with your own designs and sell them online<\/a><\/strong><\/p><p><\/p><h2>Print-on-demand factory in the UK<\/h2><h3><img src=\"https:\/\/images.teemill.com\/sysrctflumhiyyr9ik0ivfwkzuynwrdxujcki3dichpgrfwm.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"95800189\">How are printed t-shirts made?<\/h3><p>Once the blanks arrive with us, it's time to get your designs printed on them.<\/p><p>Walking into our <u><a href=\"https:\/\/teemill.com\/blog\/uk-digital-t-shirt-printing-factory\/\" target=\"_blank\" rel=\"noreferrer noopener\">digital t-shirt printing factory<\/a><\/u>, the first thing you\u2019ll notice is the tech. When we started looking into circularity, we realised that there are limits to what humans can do, how quickly, and how consistently. We only have so much time, energy and brainpower. You know what has unlimited energy and processing power? Computers.<\/p><p>So we used computers to optimise all our factories to be more efficient, more productive, and more sustainable. Products are sent all the way around the factory on a trolley system - which is also circular. That way, our team doesn\u2019t need to spend time carrying things around, what they need comes to them.<\/p><p>Our team members are the ones who maintain this tech, too, so they can adapt it to help them however they need - because the last thing we want is technology designing people out of jobs. We automate and digitise to make people\u2019s jobs easier.<\/p><p><\/p><p><img src=\"https:\/\/images.teemill.com\/a8ogzma4bio4k1i5jgffod1qhah9uxndp159fqkf4c6ytvml.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"95800238\"><br><img src=\"https:\/\/images.teemill.com\/pwkg28fnbukbahtryjlksv4iumhqptf8ekslbftghspdmzia.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"95800276\"><br><img src=\"https:\/\/images.teemill.com\/n2h8sj1ysjiywjrqu0hajigjpsjkmvc0w6x1hq5hbiegvckm.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"95800410\"><br>Our entire printing process is digital. We <u><a href=\"https:\/\/teemill.com\/blog\/print-on-demand-how-it-works-and-getting-started\/\" target=\"_blank\" rel=\"noreferrer noopener\">print on demand<\/a><\/u>, meaning nothing is made until after it has been ordered. Once a customer places an order, it is routed to the factory nearest to them as data, where it is printed within seconds.<\/p><blockquote><p>In the traditional linear economy of the fashion industry, clothes are produced speculatively, before any orders have been placed. That ends up in 40% of all clothing being created and thrown away without ever being used.<\/p><\/blockquote><p>By using print-on-demand technology, we can reduce that waste down to zero. And the cool thing about digitising the printing process is that software can be programmed to repeat the same actions every time, leading to consistent results. It\u2019s like using copy-paste, but on clothes.<\/p><p><img src=\"https:\/\/images.teemill.com\/ww8riqfrtxcdzklx1zkukd4mik78zbajkckv447x4hwlwjan.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"95800467\"><br>This tech makes our packing process 30% more efficient, saving time and, importantly, money. To make sure our products are carbon neutral, we power all our factories and manufacturing facilities using renewable energy.<\/p><p>The linear economy is so ingrained that it is now <em>more expensive<\/em> to use renewable energy, or natural materials. Instead of giving in, we designed our own tech to create these efficiencies so we could then invest in making our t-shirts sustainable.<\/p><p><\/p><h3><strong>Plant-based packaging<\/strong><\/h3><p>Instead of plastic mailers, we use packaging made from plants. It\u2019s still rip and splash-proof, to keep orders safe, but being made from natural materials it\u2019s compatible with nature. Packaging shouldn\u2019t cost the earth.<\/p><p><img src=\"https:\/\/images.teemill.com\/rsfqveoj24f0yn9ont7mwlooljekzhypef9y0wakdylnmyvn.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"\"><img src=\"https:\/\/images.teemill.com\/eyegxfhwwuwbdyguffm6slsrfqwcootd1gfltdyubzcgkx7o.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"\"><\/p><p><\/p><h2>What happens to it when it's worn out?<\/h2><p>Most brands following the linear economy model are content to wash their hands of any responsibility once the product is shipped out the door. They don't consider the end of life of that product to be any of their business, or they set up lacklustre recycling schemes that end up <a href=\"https:\/\/changingmarkets.org\/report\/trashion-the-stealth-export-of-waste-plastic-clothes-to-kenya\/\" target=\"_blank\" rel=\"noreferrer noopener\">shipping products to the global South instead of remaking them. <\/a>But what happens to those clothes when you no longer want them?<\/p><p>We believe circularity is the answer. Take back what you make, recycle it and turn it back into new products to start the cycle again.<\/p><p><img src=\"https:\/\/images.teemill.com\/3kormaw4rchxq14hi5k50jqjfqelbuchjcer0kuewmgazwep.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"\">We know that for the industry to change, <a href=\"https:\/\/teemill.com\/blog\/ted-talk-sustainability-circular-economy\/\" target=\"_blank\" rel=\"noreferrer noopener\">we need businesses to redesign their supply chains <\/a>until they reach a circular economy model. It\u2019s all about seeing those opportunities to extend the life of a product, and designing it from the start conscientiously, so that it can be used again and again and then turned into something new. That is exactly the approach we have taken with our clothing.<\/p><p>Yet, circularity isn\u2019t the answer on its own. A circle of plastic is still... Well, plastic. That exists, actually - it\u2019s called the Great Pacific Garbage Patch. Even within a circular supply chain, clothing should be plastic-free. We\u2019ve made sure that every part of our products is made from plant-based materials, from the cotton grown in our fields to the parcel that arrives at a customer\u2019s door.<\/p><h3><\/h3><h2><strong>How clothes are recycled: <a href=\"https:\/\/remillfibre.com\" target=\"_blank\" rel=\"noreferrer noopener\">Remill<\/a><\/strong><\/h2><p>Using quality materials and good clothing design means the life of clothes can be extended. With the current linear economy, clothes are worn less than 10 times before being thrown away, and then all the materials, energy and manpower that went into making them are wasted. We needed a solution that would allow us to reuse all that, so that new clothing can be made from the old.<\/p><p>We design each of our products from the start, so that they can be sent back when they\u2019re worn out and remade into new clothing. We call this process \u2018Remill\u2019. Remill means that our products can be designed, sold and worn, then sent back, remade and re-printed, and re-used\u2026 forever.<\/p><p><img src=\"https:\/\/images.teemill.com\/xxjawecg5xtv90ibtifnhbi3vj5wiwsyfmisinggeyfokpui.jpeg.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"95800612\">Each of our products comes with a tag and a barcode. Customers can scan the barcode on the label attached to their Teemill clothing, or visit our Remill <u><a href=\"https:\/\/teemill.com\/circular-fashion\/\" target=\"_blank\" rel=\"noreferrer noopener\">circular fashion page<\/a><\/u> directly. Once they input their email address, they will receive an email with instructions on how to return their item to our t-shirt factory in the UK. We cover UK shipping costs, and customers receive a discount code for their next purchase. We have already recovered over 86 thousand kg of clothing in this way.<\/p><p><img src=\"https:\/\/images.teemill.com\/1d1g1zifuudpewrx6tgibpmtftlwm5p9whjkm6p31xvzbria.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"\">When products arrive back at our factory, we separate them according to colour, and turn them back into yarn. The yarn from old products is turned into new fabric, which is then cut and sewn into a new product, ready to be printed. This allows us to make recycled products that are still just as vibrant and soft as virgin cotton. If you look closely at a Remilled product, you can actually see the mix of yarns that give the colour such a unique depth.<\/p><p><img src=\"https:\/\/images.teemill.com\/swfg5rfnlmpnkczhzawwfhzul6smatovenn3rwp85zndsesd.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"\"><img src=\"https:\/\/images.teemill.com\/ibne1t0wltahumaeobnh6xkpfmtdqpvxzhsypshsyemqjqa2.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"\">The new Remill product is 50% recycled organic cotton and 50% organic cotton, creating <a href=\"https:\/\/teemill.com\/blog\/calculating-the-environmental-impact-of-your-store\/\" target=\"_blank\" rel=\"noreferrer noopener\">massive savings<\/a> in terms of the energy and water required to create it.<\/p><p><img src=\"https:\/\/images.teemill.com\/k3xxjb1tevmy2hssayxtshpapsyjwr3qfb6klr4dak8htrtc.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"\"><\/p><p><img src=\"https:\/\/images.teemill.com\/tzlyjz8bvtg94smpcser0ijicedht0pggdsq6a6opvgcqwbi.png.jpg?w=1140&amp;h=auto\" alt=\"\" title=\"\">These Remill products can be designed through the Teemill Studio and sold through Teemill stores, then sent back again to be recycled.<\/p><p>And so the circle is complete and the journey starts all over again. The end <em>is <\/em>the start. Or the start is the end. Because what do you call a customer, when they also become your supplier? When products are sent back to us and the material is reused, we are integrating the customer into the supply chain and the circular manufacturing process.<\/p><p>We might have some terminology to work out, but what we have shown is that a circular economy is not only possible, it is financially beneficial to both companies and customers. When clothes are designed from the start to be circular, we can use fewer toxic chemicals, create less waste, be more productive and redirect our money into what counts: <a href=\"\/blog\/?search=sustainability\" target=\"_blank\" rel=\"noreferrer noopener\">sustainability<\/a>.<br><br><a href=\"\/register\/\" target=\"_blank\" rel=\"noreferrer noopener\">Setting up your online brand with Teemill <\/a>or <a href=\"https:\/\/teemill.com\/print-on-demand-api-plugins-and-integrations\/\" target=\"_blank\" rel=\"noreferrer noopener\">integrating Teemill's print on demand service<\/a> with your existing website means you get access to all of this, from our circular supply chain and high-quality products to our innovative technology and brand-building experience. All <strong>for free<\/strong>.<\/p><p><\/p><h3>\ud83d\udca1\ud83d\ude80 Ready to launch your own sustainable brand?<\/h3><p><strong><a href=\"https:\/\/teemill.com\/sign-up\/brand\" target=\"_blank\" rel=\"noreferrer noopener\">Sign up to Teemill to create your free store using our organic products<\/a><\/strong><\/p>","urlTitle":"how-t-shirts-are-made","url":"\/blog\/how-t-shirts-are-made\/","editListUrl":"\/my-blogs","editUrl":"\/my-blogs\/edit\/how-t-shirts-are-made\/","fullUrl":"https:\/\/teemill.com\/blog\/how-t-shirts-are-made\/","featured":false,"published":true,"showOnSitemap":true,"hidden":false,"visibility":{"id":1,"name":"Everywhere","code":"everywhere","created_at":null,"updated_at":null},"createdAt":1649326675,"updatedAt":1754373680,"publishedAt":1754323346,"lastReadAt":null,"division":{"id":12,"name":"Teemill"},"tags":[{"id":658,"code":"sustainability","name":"sustainability","url":"\/blog\/tagged\/sustainability\/"}],"metaImage":{"original":"https:\/\/images.podos.io\/hqweasugvyqaygjpvqn3dzfggjvtkr6oyqj5klxbl3kbeobq.jpeg","thumbnail":"https:\/\/images.podos.io\/hqweasugvyqaygjpvqn3dzfggjvtkr6oyqj5klxbl3kbeobq.jpeg.jpg?w=1140&h=855","banner":"https:\/\/images.podos.io\/hqweasugvyqaygjpvqn3dzfggjvtkr6oyqj5klxbl3kbeobq.jpeg.jpg?w=1920&h=1440"},"metaTitle":"How t-shirts are made","metaDescription":"Go behind the scenes to find out how t-shirts are made. See our sustainable manufacturing facilities, and how we've designed our circular supply chain.","keyPhraseCampaignId":43,"series":[],"similarReads":[{"id":3357,"title":"Custom robotics, automation and sustainability in our factory","url":"\/blog\/custom-robotics-automation-sustainability-uk-factory\/","urlTitle":"custom-robotics-automation-sustainability-uk-factory","division":12,"description":"Robots are amazing fun and they play a big part here at our Teemill factory. It's really important to consider technologies like this when thinking about sustainability, and we'll explain why.","published":true,"metaImage":{"thumbnail":"https:\/\/images.podos.io\/5e846553730861.26448941.jpeg.jpg?w=1140&h=855","banner":"https:\/\/images.podos.io\/5e846553730861.26448941.jpeg.jpg?w=1920&h=1440"},"hidden":0},{"id":4858,"title":"What happens after ordering a product","url":"\/blog\/what-happens-after-ordering-a-product\/","urlTitle":"what-happens-after-ordering-a-product","division":12,"description":"In this episode in our Getting Started series, we talk about what happens after you've got a sale and a product has been ordered from your store.","published":true,"metaImage":{"thumbnail":"https:\/\/images.podos.io\/5ee093a259c4e7.11843152.jpeg.jpg?w=1140&h=855","banner":"https:\/\/images.podos.io\/5ee093a259c4e7.11843152.jpeg.jpg?w=1920&h=1440"},"hidden":0},{"id":11543,"title":"Calculating the environmental impact of your store","url":"\/blog\/calculating-the-environmental-impact-of-your-store\/","urlTitle":"calculating-the-environmental-impact-of-your-store","division":12,"description":"In this blog, we explain how your Impact Stats are calculated, including the plastic your store has eliminated, the trees you have planted, the material you have saved from landfill and your net CO2 emissions. These stats are all great sources for your marketing and goal setting.","published":true,"metaImage":{"thumbnail":"https:\/\/images.podos.io\/ncneqssuzvauznyytkfyojinbqeobzsla6zaz060xu7rmawq.jpeg.jpg?w=1140&h=855","banner":"https:\/\/images.podos.io\/ncneqssuzvauznyytkfyojinbqeobzsla6zaz060xu7rmawq.jpeg.jpg?w=1920&h=1440"},"hidden":0}],"labels":[]}