Automated System for Transportation and Separation of Textile-Cutting Surpluses: A Case Study in a Portuguese Clothing Company

A significant proportion of waste generated by the fashion industry is either landfilled or incinerated, primarily due to the high cost and complexity of collecting and separating mixed textile materials. While research in textile recycling often emphasizes post-consumer waste, less attention is given to pre-consumer waste, particularly cutting surpluses generated during apparel manufacturing—a labour-intensive sector with low automation and operational inefficiencies. This study addresses this gap by presenting a case study on the implementation of an automated system for collecting, transporting, sorting, and storing textile surpluses in an apparel manufacturing environment. The research aims to identify the barriers, benefits, and sustainability impact of such automation. Using both qualitative and quantitative data, the system is evaluated through key performance indicators including time reduction, ergonomic improvement, and process reliability. Results suggest that automation enhances intralogistics, reduces non-value-added labour, and enables better utilization of human resources. This case study offers a practical framework for apparel manufacturers to assess the potential of automating textile-waste handling, helping to justify such investments based on labour use, process variability, and environmental benefits. The study contributes to the broader discourse on sustainable manufacturing and supports the apparel industry’s shift toward digital transformation and circular economy practices.