From Cotton to Your Closet: The Lifecycle of a Garment
By: Meghan Weil
Think about your favorite T-shirt or pair of jeans for a moment – have you ever wondered where they came from? What was their journey before they got to you, and where will they go once you’ve worn them out? These are questions we should ask about everything hanging in our closets. Every garment has a story, and in our effort towards a more sustainable future, we have to make sure the story is one of purpose and longevity. From the fibers to the stitching, every element of your favorite top comes from somewhere in the world, resulting in a culmination of design, labor, and environmental impact. It’s time to consider: are we truly letting our clothes live their life to the fullest?
Let’s take a look at how your favorite pair of jeans is created, starting with the raw material – cotton. The process begins with cotton, the most common fiber in denim production. Cotton is harvested from fields, typically in countries like the United States, China, and India. After harvesting, the cotton is cleaned in a process called ginning, which removes the seeds, leaving only the cotton fibers. These fibers are usually then mixed with synthetic fibers, such as polyester or elastane to give denim that stretch factor. The fibers are spun into yarn, denim yarn typically is thicker which gives the fabric its distinctive feel.
Once the cotton yarn is prepared, it moves into the warping process, where the yarn is arranged into parallel threads which form the vertical structure of the denim fabric. The yarn is wound onto large beams that feed into the weaving machines. Next, the yarn is dyed, usually with indigo. The cotton yarn is dipped multiple times into indigo dye, where it oxidizes in the air to create the deep blue color. This dyeing process gives denim its iconic hue, and depending on the number of dips, the shade of blue can vary. After dyeing, the yarn is woven into fabric using a twill weave, giving denim its characteristic diagonal pattern. The yarns are interlaced on a loom, creating a sturdy, durable fabric perfect for jeans.
After the denim is woven, it moves onto the beaming process, where the fabric is wound onto a large beam to be prepared for finishing. The fabric gets pre-washed, which softens the material and reduces shrinkage. Methods like stone-washing, enzyme-washing, or sanforization are commonly used at this stage to prepare the fabric for the final stages of finishing. Some denim may also undergo distressing techniques, such as sandblasting or acid-washing, to achieve that classic, vintage, worn-in, faded look.
Finally, once the fabric is finally finished and ready, it moves onto the next stage: cutting, sewing, and assembling the jeans. The denim is cut into pieces according to the patterns for the specific jean style, whether it’s skinny, straight-leg, or bootcut. These pieces are sewn together, and rivets, buttons, zippers, and labels are added, giving the jeans their final shape and signature look. After a final quality inspection, the jeans are pressed and packaged, ready to be shipped and eventually end up in your closet!
Now, once that process is over, the rest of its lifecycle is in our hands as consumers. This is a big responsibility because of how influential the way it's cared for impacts its lifespan. Levi’s and Reformation are two great brands to buy if you’re looking for sustainable and stylish denim. Levi’s has been making major moves toward eco-friendly production, especially with their Water<Less program, which saves tons of water during the finishing process. Their WellThread Collection uses organic cotton and recycled materials, plus they focus on ethical manufacturing, which means better conditions for the people making the clothes. They also design their jeans to last forever (or close to it), and they even offer repair services to keep them in your wardrobe longer. Reformation, on the other hand, is all about low-impact fabrics like organic cotton, tencel, and recycled materials, and they take sustainability seriously by cutting down on carbon emissions and water usage. They also push for circular fashion, meaning their jeans are made to be reused or recycled instead of ending up in a landfill. Both brands are big on transparency, so you actually know what you’re buying, and they prove that you don’t have to sacrifice style to shop more sustainably.
Most jeans, especially those from fast fashion brands, have a much shorter lifespan than we’d like to think. Once they’re worn out, out of style, or simply no longer wanted, many end up in landfills or incinerators, contributing to the massive textile waste problem. According to the EPA, millions of tons of textiles, including denim, are discarded every year, with only a small fraction being properly recycled. Fast fashion jeans, in particular, are made quickly and cheaply, often with lower-quality materials and synthetic blends that make them harder to recycle or break down naturally. Many of these jeans are sent to developing countries as part of the secondhand clothing trade, where they can overwhelm local markets and eventually end up in landfills there as well. Additionally, because denim production requires a significant amount of water and chemicals, every discarded pair represents wasted resources that took a toll on the environment. The reality is that fast fashion jeans are designed for quick turnover, not longevity, which is why choosing sustainable options, repairing, or repurposing denim is more important than ever.
At the end of the day, every piece of clothing we own has a story – where it came from, who made it, and where it will end up. As consumers, we have the power to shape that story by making more thoughtful choices. Whether it’s investing in sustainable denim, repairing instead of replacing, or simply being more mindful of what we buy, every decision matters. Our clothes are more than just fabric – they’re a reflection of the world we live in. By understanding the lifecycle of a garment, we can start making smarter, more sustainable fashion choices. Because if we truly love our favorite jeans, shouldn’t we want them – and the planet – to last?
