MAS Holdings operates a diverse ecosystem of apparel and textile business units across 14 countries catering to a range of customers with complex product needs. This position enhances our competitive edge but also presents challenges with diversified waste generation. Strongly aware of this, on our journey towards sustainable apparel manufacturing, we set ourselves a goal of achieving zero waste to landfill and enhancing the value of all our waste. By "value enhancing," we mean giving a second life to our waste through recycling (both upcycling and downcycling) and reuse. Our goal for 2025 is to transform all our waste into valuable resources, treating it as a value stream and maximizing its potential.

After achieving our zero-landfill baseline, we focused on improving value through recycling and reuse.

Early Wins and Our Progress in Circular Waste Management

In 2017, we proudly attained 100% landfill-free status for all our raw material (RM) facilities in Sri Lanka. By the end of 2023, our waste disposal profile includes 19% for reuse, 37% for recycling, 16% for internal energy recovery through steam generation in production, and 28% for external energy recovery. Our final goal is to ensure all our non-hazardous waste is value enhanced. Initiatives such as investing in a waste-to-energy boiler, developing infrastructure for sludge recovery and eco-brick production, establishing in-house composting facilities, and empowering our employees and communities with waste-to-product secondary income methods all support this goal.

As we work towards our 2025 goal of achieving 100% value enhancement of our waste, it became clear early on that current linear waste management models are unsustainable given the industry's consumption rates. Thus, we are now exploring more circular waste management solutions, focusing on recycling textile waste into raw materials, thereby keeping those textiles in use. This transition not only addresses immediate waste management challenges but also aligns with our long-term vision of fostering a circular economy within the apparel and textile sector.

Navigating the Roadblocks

As a manufacturer, the journey towards circular waste management presents unique challenges, both internally and externally.

There are operational challenges resulting from complex processes, especially from fabric cutting to fabric waste storage. Transitioning to a circular infrastructure demands substantial investment, and segregating various fabric wastes is challenging due to material composition mixes. Moreover, moving away from the current linear business model introduces complexities, particularly in balancing support for third-party waste vendors and communities. Attitude shifts and raising awareness among all stakeholders is crucial. Equally important is ensuring complete traceability and transparency in line with industry demands.

Externally, there is a lack of technological solutions that can recycle materials to the industry's required quality. And the scalability of existing recycling technologies remains a significant concern. Another challenge in our path toward circular waste management is aligning the entire supply chain to create commercially viable solutions.

A Holistic Approach to Circularity

Understanding these challenges, MAS is adopting a holistic approach under its "Plan for Change" sustainability framework.

Under the 'Sustainable Product' pillar, our team continuously seeks advanced recycling methods to convert textile waste into high-quality raw materials suitable for new textile products. These technologies span from laboratory-scale experiments to start-up ventures. We partner with them providing trial grounds to propel them to the next stage.

We have also set ourselves ambitious targets, aiming to generate 50% of revenue through sustainable products. Promoting the use of recycled materials and closing the loop on textile waste addresses the demand-pull needed for circular materials.

Our current waste management initiatives aim to harmonize our internal and external processes for effective circular waste management. This entails redesigning operational workflows, improving waste segregation practices, and upgrading infrastructure, all while collaborating with value chain partners to enable complete transparency.

One such project is the MAS KREEDA Cellucycle project. This project was launched to offer a sustainable solution for the large amounts of waste generated from cutting fleece material made of cotton and polyester. We separated the fleece fabric material at the source and successfully directed it into the recycling process, where it was converted back into yarn. This then becomes the backing yarn which can knit the same fleece material to produce the same product. This project was made possible with the help of many value chain partners within the same region and with the support of our customers.

Final Thoughts

Sustainable waste management and circularity at scale are critical components on MAS' journey to being a sustainable apparel manufacturer. We believe the future of the apparel and textile industry lies beyond addressing the immediate waste management challenges but setting a precedent for systemic change. And through experience we have seen that collective action is essential to create a lasting impact.