When you go shopping, you usually select a garment based on its trend, style, color, price, or how well it suits your personal taste. But beyond each garment, there are different types of fibers and the cost of producing the fabric itself.
Whether the product is made of natural fibers such as cotton, linen, silk, and wool, or synthetic materials like polyester, nylon, spandex, and acrylic, each fabric has a unique production journey.
Even if two garments look similar, some are available at much lower prices, while others are much more expensive. Why? Because the fabric used and its production cost can be entirely different.
We have made two-part articles for a clearer and better understanding of the topic.
Part 1 explains the difference in production costs between natural and synthetic fabrics, while Part 2 covers how consumers can avoid being misled by marketing tactics in the textile industry.
Let’s dive deeper into the article to compare the production cost of natural and synthetic fabrics.
What is the textile production cost?
Textile production cost refers to the total expense involved in making a fabric, from sourcing raw materials to finishing the final textile. The overall cost is shaped by considering factors like raw materials, energy used, labor deployed, scale of production, etc.
Understanding fabrics
Natural fabrics
Natural fabrics are those textiles made from the naturally occurring fibers of both plants and animals. They are renewable in nature and soft, breathable, biodegradable, and sustainable. Moreover, the fabrics are generally free from harmful chemicals and are safe for people.
Synthetic fabrics
Synthetic fabrics are produced from chemicals or petroleum-based compounds. These materials are strong, wrinkle-free, waterproof, and easy to care for, but they do not naturally decompose in the environment, and they can persist for hundreds of years.
Read more about different types of fabrics
Comparing the production cost of natural vs synthetic fabrics
The production cost of natural fabrics is usually higher, and the synthetic fabrics are lower because of the following factors:
Raw materials cost
Natural fibers are usually produced using labor-intensive processes. For instance, cotton harvesting involves manual labor and requires skilled workers, similar to other tasks such as wool shearing and silk reeling.
Around 200 million people are involved annually in natural fiber production, including farmers, seasonal labor, etc. This increases the overall cost of production since labor is a major part of the process. To some extent, the cost of production can even rise when work is done by hand (hand-spun/hand-woven).
In contrast, the production of synthetic fabrics is highly automated. Most of the work involved in spinning, weaving, and processing synthetic fibers is done by machines, with very limited human input.
Automation helps reduce labor costs, speeds up production, and allows for the mass production of fabrics at a much lower cost per unit.
Land usage
Natural fibers need land for growing plants or rearing animals. For example, cotton requires vast areas of land, as do other crops such as hemp or flax used in linen. Similarly, the manufacturing process for natural fabrics will involve the cost of land, farm maintenance, and equipment. Additionally, organic production methods to produce organic cotton or linen raise the cost even higher because of their careful management.
According to a Fibre & Special Crops report, fiber crops, including cotton, jute, flax, agave, sisal, ramie, etc., cover ~34.2 million hectares globally.
Synthetic fibers are manufactured in factories and therefore do not require agricultural land. Since they are derived from chemical processes and not from plants or animals, there will be no need for land to be utilized for growth or cultivation. This cuts down the cost of land use.
Water and energy usage
Most natural fibers, especially cotton, require huge volumes of water for their growth. At the processing stage, these fibers undergo water- and energy-intensive processes like washing, spinning, and dyeing.
These can make the processing of natural fibers particularly expensive, especially in areas where water is expensive to access.
While synthetic fabric manufacturing requires a lot of energy, the water requirement is usually not as high. The mass production enables factories to use energy effectively, and the overall cost per unit of fabric is much lower. It remains more cost-effective than natural fibers.
Production scale
Natural fabrics are produced on a much smaller scale compared to synthetic fibers. The dependence on farming and seasonal variations also means that natural fibers are produced in batches, often based on the annual harvest cycle.
Approximately 31% of natural fibers are produced worldwide, including plant-based and animal-based. In that, cotton is the top natural fiber, making up ~19% of global fiber production in 2024.
Synthetic fibers have much higher production volumes. In the most recent year, approximately 69% of all fiber production was synthetic. Polyester is the most produced synthetic fiber, accounting for ~59% of total global fiber output in 2024. The ability to manufacture huge quantities of fabrics in a very short time makes the per-unit cost much lower when compared to natural fabrics.
How can we choose better?
Choosing better fabrics involves understanding that low textile production cost does not always translate to better value. Synthetic materials may be cheap, but they contribute to issues like microplastic pollution, carbon emissions, and overflowing landfills, and they do not break down easily.
While being costly, natural fibers have a lot of benefits. They are biodegradable, gentle on the skin, and free of microplastic shedding. They also support farmers and artisans, whose livelihoods depend on growing and crafting those materials.
When buying garments, pay attention to textile labels and choose higher-quality items. Taking good care of your clothes helps them last longer and is better for both the planet and the people.
At Green Tailor, every purchase is a chance to make a positive impact. All our ready-to-dye natural fabrics and products respect the planet while being safe for you. Join us in creating a future where quality and sustainability go hand in hand. Shop smarter and wear better!
For any queries, feel free to contact us at [email protected].
