Recycled Polyester T-Shirt

Material Composition Assumptions

The recycled polyester t-shirt consists primarily of post-consumer recycled polyester derived from plastic bottles, representing approximately 95% of the total weight at 142 grams. Elastic fibers used in cuffs and waistband contribute roughly 3% of the material composition at 4.5 grams. Thread for seaming accounts for the remaining 2% at approximately 3 grams, bringing the total garment weight to 150 grams.

The recycled polyester component undergoes mechanical processing to convert discarded plastic bottles into textile-grade fibers. This process requires significantly less energy than virgin polyester production while maintaining comparable performance characteristics for apparel applications.

Manufacturing Geography

Primary manufacturing occurs in China, where the majority of global textile production facilities are concentrated. The Chinese electrical grid operates at an intensity of 555 gCO2/kWh, reflecting the country’s heavy reliance on coal-fired power generation for industrial processes.

This manufacturing location is selected due to established infrastructure for both plastic waste processing and textile production, along with proximity to major polyester fiber production facilities. The integration of recycling operations with garment manufacturing reduces transportation emissions between processing stages.

Regional Variation

Manufacturing Region	Grid Intensity	Estimated CCI Score	Adjustment vs Default
China	555 gCO2/kWh	4.8	Baseline
India	708 gCO2/kWh	5.2	+8%
Turkey	387 gCO2/kWh	4.3	-10%
Portugal	252 gCO2/kWh	3.9	-19%
Costa Rica	89 gCO2/kWh	3.4	-29%

Provenance Override Guidance

1. Verified recycled content percentage with third-party certification demonstrating actual post-consumer plastic bottle input ratios
2. Manufacturing facility electricity source documentation including renewable energy procurement contracts or on-site generation capacity
3. Fabric dyeing process specifications detailing water treatment methods, chemical usage, and energy consumption per kilogram of finished product
4. Transportation logistics data covering shipping modes, distances, and fuel consumption from fiber production through retail distribution
5. Washing instruction recommendations with supporting data on garment durability under reduced washing frequency protocols

Methodology Notes

• The CCI score represents cradle-to-grave emissions including manufacturing, transportation, consumer use phase, and end-of-life disposal over an assumed 50-wash lifecycle
• Scope 3 dominates the emissions profile due to repeated washing cycles requiring heated water and mechanical drying processes
• Functional unit basis assumes standard adult medium size t-shirt weighing 150 grams with typical consumer washing behavior patterns
• Score excludes retail infrastructure, packaging materials, and consumer transportation to point of purchase
• Data gaps exist for regional variations in washing machine efficiency and local water heating energy sources across different markets
• The recycled content assumption may vary significantly between suppliers, with virgin polyester blending potentially increasing the carbon intensity by up to 15% per percentage point of non-recycled content