Stitching Sustainability: How Organizational Life Cycle Assessment Reveals Hidden Impacts in Fashion SMEs

Abstract

Organisations across industries are under growing pressure to reduce their environmental footprints. However, identifying true environmental “hotspots” is far from simple. Many sustainability initiatives risk shifting impacts from one stage of the value chain to another — reducing carbon emissions, for example, while increasing water use or toxicity elsewhere. This is where Organizational Life Cycle Assessment (O-LCA) becomes a powerful decision-making framework.

This case study applies the principles of ISO 14040 and ISO 14044, along with organizational guidance from ISO/TS 14072, to evaluate the full 2023 operational output of a fashion industry SME. Unlike product-level LCAs, this assessment takes a whole-organisation perspective, mapping all gate-to-gate material and energy flows associated with the firm’s annual production.

Methodological Approach

The study followed a structured O-LCA framework:

  • Data Collection: Primary inputs and emissions compiled directly on-site

  • System Boundary: Gate-to-gate flows covering total 2023 production

  • Modelling Software: SimaPro (version 9.1.1)

  • Database Used: Ecoinvent – allocation, cut-off system model

  • Impact Assessment Method: ReCiPe 2016 Midpoint (H)

  • Impact Categories Analysed: 18 environmental impact categories

 

This comprehensive approach ensured that multiple environmental dimensions — not just climate change — were evaluated.

 

Key Findings: Where Are the Real Environmental Hotspots?

The results reveal several critical insights for fashion SMEs:

1. Electricity Consumption – The Primary Climate Driver

  • Contributes 43.5% to total climate change impacts

  • Represents the most significant carbon hotspot in operations

Practical Example:
A small fashion manufacturer using grid electricity for cutting, stitching, ironing, and packaging may unknowingly generate nearly half of its climate footprint from energy use alone.

2. Cotton Fibre – A Major Water & Eutrophication Contributor

  • 87.3% of freshwater eutrophication impact

  • 37.8% of total water consumption

Cotton cultivation is resource-intensive, especially in regions with irrigation dependency and fertilizer use.

Real-World Context:
For an Italian SME sourcing conventional cotton fabric, upstream agricultural practices (fertilizer runoff, irrigation systems) heavily influence overall environmental performance — even though those processes occur outside the factory walls.

3. Potential Reduction Strategy

Combined interventions could reduce the organisation’s total climate footprint by up to 34.6%, including:

  • Transitioning to renewable electricity (e.g., rooftop solar systems)

  • Increasing recycled fibre content (recycled polyester, recycled cotton blends)


Strategic Recommendations from the Case

The analysis highlights actionable improvement pathways:

  • Transition to renewable electricity sources (e.g., solar installations)

  • Source cotton from water-efficient or certified green suppliers

  • Increase recycled polyester and alternative fibres

  • Explore material substitution for brass components where feasible

These recommendations are particularly relevant for SMEs, as they balance environmental gains with operational feasibility.


Why This Study Matters Beyond One Company

Although conducted within a single fashion SME context, the methodology and insights are highly transferable. Many small and medium enterprises in Italy and across Europe face similar:

  • Limited sustainability reporting capacity

  • Heavy upstream supply chain impacts

     

  • Energy-intensive manufacturing processes

By adopting Life Cycle–based methodologies like O-LCA, peer companies can:

  • Identify true hotspots

  • Avoid burden shifting

  • Make data-driven sustainability investments

  • Align with evolving EU sustainability reporting expectations

     

Broader Insight for the Fashion Industry

This case demonstrates that environmental responsibility in fashion is not only about switching materials or reducing packaging. It requires a system-level understanding of organisational flows, integrating energy, raw materials, suppliers, and operational decisions into one coherent environmental performance model.

In the following sections of this blog, we will explore how this O-LCA was structured, what challenges emerged during implementation, and what fashion SMEs can practically learn from this approach.

1. Introduction

 

The fashion industry stands as one of the most influential economic sectors globally, generating approximately $3 trillion annually and contributing nearly 2% of global GDP. Yet, its environmental footprint is equally significant. The sector is estimated to account for 9% of global greenhouse gas emissions and nearly 20% of worldwide water pollution, largely due to energy-intensive manufacturing and chemical-heavy textile processing.

These impacts are further intensified by fast-fashion business models, which:

  • Accelerate production cycles

  • Shorten product lifespans

  • Increase textile waste

  • Complicate end-of-life management

Global clothing production has roughly doubled since 2000, while the average number of times a garment is worn has dropped by approximately 40%. Some ultra-fast fashion items are discarded after just 7–10 wears, reflecting a linear consumption pattern that amplifies resource depletion and waste generation.

 


Growing Regulatory and Market Pressure in Europe

The sustainability debate in fashion is no longer voluntary — it is regulatory, financial, and consumer-driven.

Nearly six in ten EU citizens report willingness to pay more for sustainably produced and repairable products. This shifting consumer mindset aligns with major policy reforms across the European Union.

Several key regulatory developments are reshaping accountability:

  • Separate collection of post-consumer textiles mandated from January 2025 under the amended Waste Framework Directive

  • Introduction of eco-modulated Extended Producer Responsibility (EPR) schemes for textiles

  • Phased sustainability reporting beginning 2025 under the Corporate Sustainability Reporting Directive

  • Mandatory compliance with European Sustainability Reporting Standards

  • Compulsory Digital Product Passports for textiles sold in the EU market

These measures signal a fundamental shift: environmental accountability is moving from individual products toward full organisational responsibility.

For fashion SMEs — particularly those embedded in subcontracting networks like Italy’s manufacturing ecosystem — this transformation presents both a challenge and an opportunity.

 


The Data Gap in Fashion Sustainability

Despite increasing commitments, organisations struggle with a persistent issue:

A lack of comprehensive, reliable data across their value chains.

This data scarcity limits informed decision-making and weakens credibility. A forensic review of voluntary climate targets revealed that by the end of 2024, only one-third of 2020 voluntary targets showed credible progress evidence.

Moreover:

  • Investors increasingly request cradle-to-gate environmental metrics

  • Global platforms demand quantifiable impact disclosures

  • Yet few life cycle studies in fashion adopt an Organizational LCA (O-LCA) perspective

  • Almost none focus on a real fashion SME

There remains limited empirical research demonstrating how environmental hotspots can be:

  • Identified

  • Quantified

  • Strategically acted upon

— particularly at the SME level.

 


Why Organizational LCA (O-LCA) Matters

To address this gap, this study applies Organizational Life Cycle Assessment (O-LCA), guided by:

  • ISO 14040

  • ISO 14044

  • ISO/TS 14072

O-LCA extends traditional product-level LCA thinking to the entire organisation, analysing:

  • All inputs (materials, energy, water)

  • All outputs (products, emissions, waste)

  • Potential environmental impacts across the life cycle

Although O-LCA does not define a functional unit — limiting direct comparisons between different companies — it remains extremely valuable for:

  • Year-by-year internal benchmarking

  • Tracking environmental performance trends

  • Identifying strategic intervention points

This perspective is particularly relevant in Italy’s fashion ecosystem, which is dominated by networks of specialised subcontracting SMEs. In such systems, upstream and downstream impacts are often fragmented, making holistic assessment indispensable.

 


Study Objectives

Using SimaPro and the Ecoinvent database, this case study conducts an Organizational LCA of an Italian apparel SME with three primary objectives:

  1. Identify the main activities driving environmental impacts within fashion SMEs

  2. Demonstrate how O-LCA effectively quantifies and prioritizes hotspots

  3. Show that adopting O-LCA delivers managerial and strategic value, not just reporting compliance

The study expands existing O-LCA research by:

  • Applying a hybrid inventory approach

  • Integrating activity-based reporting

  • Aligning with UNEP-SETAC Life Cycle Initiative guidance

  • Operating despite limited SME-level data availability

Most importantly, it translates environmental metrics into actionable business recommendations, including:

  • Transitioning to renewable electricity

  • Improving fibre sourcing strategies

  • Strengthening supplier engagement

 


Bridging Measurement and Strategy

This research responds to the urgent need for sector-specific, SME-centred evidence. By grounding methodological rigor in real operational constraints, it demonstrates that O-LCA is not merely a reporting tool — it is a strategic management instrument.

For fashion SMEs navigating regulatory pressure, investor scrutiny, and consumer expectations, Organizational LCA provides a structured pathway to:

  • Avoid burden shifting

  • Prioritize high-impact interventions

  • Align sustainability with competitiveness

In the next section, we will examine how the methodological framework was adapted to the realities of an Italian fashion SME and how system boundaries were defined for meaningful organisational assessment.

 

2. Methods

This study applies Organizational Life Cycle Assessment (O-LCA) as a structured methodology to quantify the environmental impacts of a fashion SME. O-LCA can be applied to any entity — companies, partnerships, or institutions — regardless of size or legal structure.

The methodological framework follows:

  • ISO 14040

  • ISO 14044

  • ISO/TS 14072

The approach mirrors traditional product LCA but expands the perspective to the entire organisation.

The Four Phases Applied

The study follows the classic LCA structure:

Goal and Scope Definition
Defines motivation, intended audience, system boundaries, and reporting flow.

Life Cycle Inventory (LCI)
Compiles all relevant inputs and outputs across direct, upstream, and downstream activities.

Life Cycle Impact Assessment (LCIA)
Translates inventory flows into environmental impact indicators.

Interpretation
Identifies hotspots, limitations, and strategic recommendations.

2.1 Goal and Scope Definition

Company Profile

The analysed company (name withheld for confidentiality) is:

  • Located in the Marche Region, Italy

  • 2023 turnover: €5 million

  • Activity: Assembly and finishing of high-quality apparel (especially jeans) for major brands

  • Study reference year: 2023

  • Analysis period: February–September 2024

The firm specializes in:

  • Prototyping (on demand)

  • Manufacturing

  • Garment finishing

  • Quality control

It operates within Italy’s subcontracting-based fashion ecosystem.

Production Output (2023)

The total annual output amounted to:

  • 62,463 pieces

  • 27,458.34 kg of final products

The reporting flow — as recommended in O-LCA guidance — is based on total annual production weight (kg) rather than a functional unit.

Main Product Categories

Product Type

Quantity

Weight (kg)

Men’s Pants

14,636

8,049.80

Women’s Pants

7,736

3,403.84

Children’s Pants

16,551

3,310.20

Adult Jackets

3,410

2,046.00

Boots

5,450

5,450.00

Others (skirts, shirts, dresses, bags, belts)

Remaining share

Total

62,463

27,458.34 kg


Production Process Overview

The organisational production flow includes:

  1. Market research and material sampling

  2. Prototyping and sample validation

  3. Order confirmation and sourcing

  4. Cutting, sewing, and assembly

  5. Finishing and quality control

  6. Packaging

Smaller batches are finished in-house, while larger volumes may be outsourced.

⚠️ Important: The system boundary includes direct production activities only, due to limited upstream and downstream data availability. This decision aligns with Clause 5.2.2 of ISO/TS 14072 and UNEP-SETAC guidance.

2.2 Life Cycle Inventory (LCI)

The Life Cycle Inventory phase compiles all material, energy, and emission flows within defined system boundaries.

According to ISO 14040 and ISO 14044, LCI involves:

  • Quantifying raw materials

  • Measuring energy consumption

  • Tracking water use

  • Accounting for emissions and waste

Data Collection Strategy

Due to low digitalisation and lack of historical environmental monitoring, the study relied primarily on secondary data.

Data Collection Activities

  • On-site visit

  • Employee interviews

  • Company-specific questionnaire

  • Market research and literature review

  • Mapping of organizational structure

Secondary datasets were sourced from:

  • Ecoinvent

This reliance on secondary data highlights a common SME challenge:

Environmental data is often fragmented, incomplete, or non-digitized.

 


Key Assumptions in Inventory Modelling

To address data gaps, several justified assumptions were made:

Fibre Composition

  • Only cotton and polyester considered dominant fibres

  • Elastane (0.07%) treated as negligible and classified under cotton

This simplification aligns with industry literature.

Accessories

  • Buckles, rivets, and buttons assumed to be primarily brass, due to lack of specification.

Such assumptions were necessary to maintain modelling completeness while acknowledging limitations.

 

Major Inputs Identified

Materials (Technosphere Inputs)

  • Cotton fibre (organic)

  • Polyester fibre

  • Brass

  • Packaging materials (carton board, corrugated board, kraft paper)

  • Polyester resin

  • Polyethylene granulates

  • Natural gas

  • Diesel

  • Deionised water

Electricity Consumption

  • 238,206 kWh (low voltage, Italy)

This electricity input later emerged as a major environmental hotspot.

2.3 Life Cycle Impact Assessment (LCIA)

 The Impact Assessment phase translates inventory flows into environmental impacts.

For this study:

  • Impact Method: ReCiPe 2016 Midpoint (H)

  • Database: Ecoinvent (allocation, cut-off system model)

  • Software: SimaPro version 9.1.1

Why ReCiPe 2016 Midpoint?

ReCiPe Midpoint was selected because:

  • It is widely used in apparel LCAs published after 2020

  • It improves comparability across studies

  • It avoids subjective weighting steps used in endpoint methods

  • It enables clear hotspot identification

Impact Categories Assessed

The method evaluates 18 midpoint impact categories, including:

  • Climate change

  • Freshwater eutrophication

  • Water consumption

  • Fossil resource scarcity

  • Human toxicity

  • Terrestrial acidification

Midpoint indicators assess impacts at intermediate stages, allowing:

✔ Transparent environmental diagnosis
✔ Clear ranking of hotspots
✔ Reduced value-laden interpretation

 


Methodological Significance

This structured approach demonstrates that even with:

  • Limited primary data

  • SME-level constraints

  • Partial system boundaries

— O-LCA can still generate strategic, decision-relevant insights.

The methodology bridges:

  • Academic rigor

  • Real-world SME constraints

  • Regulatory alignment

  • Managerial applicability

 


In the next section, we will analyse the results and identify the environmental hotspots that drive the majority of the organisation’s impact — and how these findings translate into strategic action for fashion SMEs.

 

3. Results and Discussion

The Results and Discussion phase translates the Life Cycle Inventory (LCI) data into environmental meaning. Through the characterization process, material and energy flows are converted into potential environmental impacts. This allows the identification of environmental hotspots.

Subsequently, normalization compares these results to reference values, helping prioritise which impact categories are most significant relative to broader environmental burdens.

Together, characterization and normalization transform raw inventory data into actionable sustainability insights.

 

3.1 Characterization Results

Table 3 presents the environmental impacts per unit of final product.

Key Impact Results (per unit of product)

Impact Category

Value

Unit

Global Warming

8.46

kg CO₂-eq

Stratospheric Ozone Depletion

5.06×10⁻⁵

kg CFC11-eq

Ionizing Radiation

0.57

kBq Co-60 eq

Fine Particulate Matter

0.01

kg PM2.5 eq

Freshwater Eutrophication

0.02

kg P eq

Marine Eutrophication

0.03

kg N eq

Terrestrial Ecotoxicity

33.74

kg 1,4-DCB

Human Non-Carcinogenic Toxicity

9.32

kg 1,4-DCB

Land Use

18.09

m² crop eq

Fossil Resource Scarcity

3.52

kg oil eq

Water Consumption

0.20

Impact modelling was performed using ReCiPe 2016 Midpoint (H) within SimaPro, using Ecoinvent datasets.

 


Environmental Hotspot Analysis

Global Warming Potential (GWP)

Baseline: 8.46 kg CO₂-eq per unit

Main contributors:

  • Electricity → 43.5%

  • Polyester resin

  • Cotton fibre

     

The polyester–electricity combination mirrors findings in recent apparel LCAs, where synthetic fibres and fossil-based electricity account for 55–70% of GWP in knitwear systems.

Why?

  • Polyester production is energy-intensive (PET spinning route).

  • Electricity mix still contains fossil fuels.

  • Cotton cultivation adds indirect emissions (fertilisers, field emissions).

Insight: Climate impact is both energy-driven and material-driven.

 

Freshwater Eutrophication

Dominated by:

  • Cotton fibre → 87.3%

Cause:

  • Nitrogen and phosphorus runoff from agriculture.

  • Fertilizer-intensive cultivation practices.

This confirms literature findings showing cotton agriculture as a major contributor to nutrient pollution, especially in regions with intensive monoculture.

Insight: Even “natural fibres” carry substantial upstream environmental burdens.

 

Water Consumption

  • Cotton fibre → 37.8%

  • Polyester resin → secondary contributor

Insight: Cotton’s irrigation requirements significantly drive water use impacts.

 

Toxicity Categories

Human Non-Carcinogenic Toxicity

  • Brass → 49.3%

  • Electricity

  • Polyester resin

Metal extraction and processing for accessories become visible only when aggregated at annual organisational scale — something product LCAs often underestimate.

Marine Ecotoxicity

  • Electricity → 51.1%

  • Brass → 15%

  • Polyester resin

Metal emissions and chemical discharges from synthetic fibre production drive these impacts.

 

Ozone Depletion

Main contributors:

  • Polyester → ~45%

  • Electricity → ~25%

  • Cotton yarn → ~10%

Virgin polyester production releases trace ozone-depleting substances during chemical processing.

Normalization: What Truly Matters?

Normalization compares each category relative to a reference environmental burden.

Key insights:

  • Freshwater eutrophication stands out prominently.

     

  • Cotton dominates eutrophication.

     

  • Electricity remains central for climate and toxicity impacts.

     

  • Polyester influences ozone depletion and marine ecotoxicity.

     

This step confirms that:

Cotton and electricity are the primary organisational hotspots.

 

Strategic Interpretation of Results

Electricity: The Most Manageable Lever

Electricity contributes:

  • 43.5% of GWP

  • 51.4% of carcinogenic toxicity

  • 53.2% of freshwater ecotoxicity

Because electricity procurement is operationally adjustable, it represents the short-term strategic lever.

If renewable electricity replaces the current mix:

  • GWP could drop by ~30% of electricity’s contribution.

  • Organisational climate footprint reduction ≈ 30–35%.

This aligns with apparel sector decarbonisation roadmaps.

 


Cotton: The Agricultural Challenge

Cotton drives:

  • 87.3% freshwater eutrophication

  • 37.8% water consumption

  • 96.8% marine eutrophication (organic cotton context)

Mitigation pathways:

  • Supplier selection based on irrigation efficiency

  • Precision agriculture partnerships

  • Certified sustainable cotton (e.g., GOTS)

  • Increased recycled cotton use

     

Precision-irrigated cotton could reduce eutrophication loads by ~35%.

 


Polyester: Synthetic Fibre Trade-Off

Polyester contributes to:

  • Ozone depletion (33.4%)

  • Carcinogenic toxicity (20.8%)

  • Marine ecotoxicity (11.1%)

Switching to recycled polyester and improving recycling technologies could reduce impacts by ~35%.

Combined with renewable electricity:

➡ Potential total GWP reduction ≈ 34.6%

Sensitivity Analysis

To test robustness, electricity impacts were varied ±30%.

Results:

Impact

Baseline

Cleaner Mix (-30%)

Fossil-Heavy Mix (+30%)

GWP

8.46

7.36

9.56

Freshwater Ecotoxicity

0.67

0.56

0.78

Marine Ecotoxicity

0.87

0.74

1.00

Findings:

  • Absolute values vary.

     

  • Hotspot ranking remains stable.

     

  • Electricity remains dominant driver.

     

This confirms methodological robustness despite reliance on secondary data.

 

3.2 Interpretation

The OLCA identified two main hotspots:

  1. Electricity use

  2. Cotton fibre sourcing

Recommended Actions

Transition to Renewable Energy

  • Solar installation or renewable procurement contracts

  • Expected GWP reduction: ~30% of electricity contribution

Sustainable Cotton Strategy

  • Partner with water-efficient suppliers

  • Adopt certified organic systems

  • Increase recycled cotton share

Polyester Improvements

  • Increase recycled content

  • Explore bio-based alternatives

     

Material Substitution

  • Replace brass with aluminium where feasible

  • Implement cleaner production technologies

 


Digitalisation as an Enabler

A major limitation was reliance on secondary data.

To improve:

  • IoT-enabled energy monitoring

  • Blockchain-based supplier tracking

  • Digital compliance integration for Corporate Sustainability Reporting Directive

  • Alignment with European Sustainability Reporting Standards

     

Digital tools would strengthen:

 

  • Data precision

  • Reporting reliability

  • Strategic monitoring

4. Conclusions

This study demonstrates that Organizational LCA is both feasible and strategically valuable for fashion SMEs, even under data constraints.

Key confirmations:

OLCA effectively identifies organisational hotspots
It supports managerial decision-making
It enhances regulatory preparedness
It builds internal sustainability capacity

Beyond environmental metrics, OLCA acted as a capacity-building mechanism, improving awareness and triggering internal strategic shifts:

  • Renewable electricity discussions initiated

  • First sustainability reporting efforts drafted

  • Commitment to repeat OLCA for year-on-year comparison

 


Broader Implication for Fashion SMEs

OLCA bridges:

  • Environmental science

  • Regulatory compliance

  • Strategic management

     

  • Operational decision-making

For Italian and European fashion SMEs navigating CSRD, ESRS, and digital passport requirements, OLCA represents:

A practical, scalable, and forward-looking sustainability instrument.

Future research should:

  • Expand to multi-year assessments

  • Increase primary data integration

  • Integrate OLCA outputs into digital product passports

  • Explore circular business model innovations

 


Final Reflection

This case confirms that sustainability in fashion is not only about greener fabrics — it is about organisational transformation through system-level understanding.

OLCA provides the structure to make that transformation measurable, strategic, and actionable.

Source: This analysis is based on the peer-reviewed article published in Research Gate, Organizational life cycle assessment: A case study in the fashion industry small and medium enterprises

 

Available at: https://www.sciencedirect.com/science/article/pii/S2666016425002208

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