The reality of apparel waste: From mass waste to a circular society: the sustainable future we must choose now

Introduction: From Guilt to Choice

In recent years, the mass disposal of clothing has become a serious problem in the apparel industry. Due to the rapid expansion of fast fashion and extremely short trend cycles, large amounts of still-wearable clothing are being discarded , and the environmental impact and social costs associated with its disposal are increasing.

"I feel guilty every time I buy clothes" or "I want to make sustainable choices, but I don't know where to start" - this article answers such questions by explaining the current situation, identifying the causes, and implementing solutions . By the time you finish reading, you'll understand why apparel waste is closely linked to each individual's choices , and you'll have a clear idea of ​​the actions you can take starting today .

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1. The current state of apparel waste and its social impact

1-1. Increasing waste

In Japan, around 800,000 tons of clothing are discarded annually , with approximately 60% of this being incinerated or disposed of in landfills . As much of this clothing is still wearable, this not only results in resource waste , but also in CO₂ emissions, the release of hazardous substances, and increased costs for local governments .

1-2. Waste occurs throughout the supply chain

Waste does not simply mean "throwing away clothes you no longer wear." It occurs in every aspect of production, distribution, and consumption .

The challenge is that unless this overall picture is grasped, countermeasures will likely fall into partial optimization .

1-3. Environmental impact and social costs

• Incineration : CO₂ emissions, harmful substances when synthetic fibers are burned

• Landfill : Long-term residue of chemical fibers that are difficult to decompose, affecting soil and water quality

• Social costs : Local governments are burdened with the costs of collection, transportation, and disposal, and as long as disposal continues, the " make and throw away " cycle will be strengthened, making it more difficult to realize a recycling-oriented society.

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2. Why waste disposal continues (the structure of causes)

2-1. Excessive acceleration of the trend

Short trend cycles mean that more clothes become "old" in just a few months, and fewer clothes are worn , leading to more discards.

2-2. Mass production based on the assumption that products will remain unsold

Excessive inventory in order to make the sales floor appear larger will ultimately result in write-downs and waste . It is essential to design production and sales that do not assume inventory .

2-3. Low-cost, low-durability materials and stitching

Synthetic fibers and low durability are disadvantageous in terms of both a short lifespan and the burden placed on the body during processing. Designs that cannot be worn for long periods of time hinder circulation.

2-4. Changes in consumption patterns

The trend toward "always new products" in the age of social media is accelerating short-cycle consumption . Meanwhile, ethical thinking is spreading, especially among Gen Z and millennials, and is becoming a key driver of change .

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3. Reasons why recycling is difficult to advance (technology, costs, systems)

3-1. Technical hurdles: material mixing

Composite materials such as polyester and cotton are difficult to separate and decompose , which is why it is difficult to increase the recycling rate compared to paper and metal.

3-2. Cost traceability

The costs of the process of sorting, collection, and reprocessing remain high, and the opacity of the supply chain prevents the company from gaining social trust.

3-3. Current state of advanced recycling

Chemical recycling and fiber-to-fiber are making progress, but there will be a time lag before they become widespread , so we need immediate solutions to bridge the gap .

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4. Corporate Solutions: Designing an Exit from Overproduction (OLDFLIP)

It is a practical solution that should be positioned immediately after the "mass production model that assumes unsold goods." OLDFLIP supports the minimization of inventory value loss and circular monetization by combining the following to guide unsold stock, B-grade products, returned goods, etc. back into circulation rather than discarding them.

• Regeneration by black dyeing (Black Dye)
  Products that have become difficult to sell due to stains, color variations, sun damage, uneven coloring, etc. can be re-dyed to a deep black , resetting the uneven appearance . They can be re-proposed as a versatile "black" and regaining the possibility of resale .
  → Service details: https://oldflip.co.jp/blogs/service/black

• Reconstruction Remake (Brand: zivun)
  We dismantle and re-edit inventory that is difficult to resell individually, redefining its value as one-of-a-kind/small-lot limited items . In collaboration with designers and fashion students, we transform "items scheduled for disposal into works of art."
  → Service details: https://oldflip.co.jp/collections/hk
  
  

• Complete operation
  We provide one-stop support for collection, sorting, processing (black dyeing, reconstruction), and sales (EC and brick-and-mortar stores) . We design optimal formulations for each SKU in line with existing MD and sales channels.

• Collaborative capsule collections <br data-start="2350" data-end="2353">We plan collaborative capsule collections using materials from corporate inventory. We help visualize initiatives in the context of public relations/PR/ESG disclosure .
  →Contact: https://oldflip.co.jp/pages/contact

• Installation flow (example)

  1. Inventory visualization and classification (regular resale/suitable for black dyeing/suitable for reconstruction)

  2. Small lot verification (SKU limited testing → verify demand, gross profit, and turnover)

  3. Refining formulations (optimizing yield, lead time, and costs)

  4. Mass production scale (continuous SKU expansion, incorporation into MD by sales channel)

  5. Traceability disclosure (making it possible to explain the collection, recycling, and sales process)

• Operational Considerations <br data-start="2638" data-end="2641"> We provide practical support for quality standards (fastness, color fading, stitching strength), laws and regulations and labeling (composition, secondary processing), brand guideline alignment, and designs that appeal to existing customers (positioning of recycled products).

Effects : Reduced incineration and landfill waste / Reduced inventory valuation losses / Improved resale rate / Gross profit recovery .
Key point : Not only "not producing" but also "responsible exit design after production" will accelerate the transition to circular economy.

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5. Upcycling: A quick solution alongside cutting-edge recycling

Upcycling, which does not require material separation , has the advantage of being easy to implement on-site, as it shortens the distance from collection to sale. OLDFLIP's black dyeing process absorbs color unevenness and sun damage through its design , and reconstruction (zivun) extends the lifespan by selecting healthy parts .


Meanwhile, cutting-edge technologies such as chemical recycling are promising long-term solutions . A realistic strategy is to quickly lower the waste reduction curve by adopting a two-tiered approach: "upcycling now" and "looking to the future" (recycling) .

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6. Towards a circular economy: What businesses and consumers can do

6-1. Company implementation steps

• Orders/optimal inventory : Structural control of overproduction

• Enhanced traceability : Visualization of collection, recycling, and sales

• Establishment of inventory recycling routes : Standardization of redistribution through black dyeing/reconstruction

• Small-lot verification → Mass production : Start small and gain internal agreement

• ESG storytelling : A series of steps from disclosure, PR, and internal penetration

For businesses : We can test the regeneration of inventory, B-grade products, and recalled products in small lots . First, please let us know your inventory status and desired sales channels.
Details of black dyeing: https://www.k-rewear.jp/somekae/?ca=1648512673-152237

6-2. What consumers can do starting today

• Choose a piece that you can wear for a long time (based on the material, stitching, and whether it can be repaired)

• Participate in collection and reuse (brand collection/local collection/secondary distribution)

• Choose unique items : Opting for upcycled items (e.g., zivun), dyed black, reconstructed, etc., is the quickest route to sustainability .

Consumer Choice: zivun
Give clothes that would otherwise be thrown away a new story . Choosing unique items that you can cherish for a long time is the most accessible climate action.

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7. Common Misconceptions and Solutions (Mini FAQ)

• Q. Isn't black dyeing just a cover-up?
  A.It is a technique that reunifies the uneven appearance of a product through design , and simultaneously enhances its functional value (extended service life) and emotional value (satisfaction of ownership).

• Q. Reconstruction seems time-consuming and expensive.
  A. By testing small lots and then mass-producing continuous SKUs , we can improve yield, cost, and turnover . Only after including the exit design can we establish business viability.

• Q. Is widespread adoption of advanced recycling enough?
  A. There is a time lag before waste becomes widespread, so we need an immediate solution to stop the inflow of waste right now . Only by running alongside upcycling can the curve decline.

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8. Summary: Turning waste into value, starting today

The increase in apparel waste poses a complex challenge, with environmental impact, human rights, and social costs . Recycling alone takes time due to barriers such as complex materials, cost, and transparency .

That is why it is important to incorporate the immediate upcycling of black dyeing and reconstruction into our business operations, and to approach this with both a "no production" design and an "exit after production" design .
Companies should improve their order, inventory, and recycling routes, while consumers should choose long-lasting items and upcycled products, and participate in collection and reuse programs.

**Disposal is not an "unavoidable cost." **By changing the way we think and implement it, it can become a source of value . OLDFLIP designs recycling on-site together, setting the standard for the future now.

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