The textile sector is grappling with a daunting carbon footprint, with more than half of its energy consumed in heating processes powered by fossil fuels. Recent research from GEI (2024) confirms that electrification only reduces emissions when the electricity is sourced from clean energy. This article expands on that insight, drawing on Vu Phong Energy Group’s expertise to explore practical pathways and real‑world case studies that demonstrate how textile manufacturers can transition to renewable‑powered electrification, slash CO₂ emissions, and strengthen supply‑chain sustainability.
The GEI study (2024) emphasizes that electrification only genuinely reduces emissions when the electricity source comes from clean energy. If the grid still contains a large proportion of fossil fuels, the transition may not reduce emissions in the short term (until 2030).
The textile industry faces immense pressure to reduce carbon emissions and transition to sustainable production. With over half of the industry’s energy demand coming from thermal processes (dyeing, drying, heating, finishing, etc.), electrification with clean energy – replacing fossil fuels with electrical equipment using renewable electricity – is emerging as a core solution to help the industry achieve its Net Zero goals.
According to the latest studies by Global Efficiency Intelligence (GEI, 2024-2025) and WWF-H&M Group (2024), electrification can reduce CO₂ emissions by up to 50%, increase energy efficiency, and improve occupational safety, especially when combined with clean electricity sources from solar or wind power. This makes electrifying the textile industry for net zero a critical pathway.
Textile Industry: Enormous Thermal Demand and Carbon Emission Hotspots
The global textile industry currently accounts for approximately 4% of total greenhouse gas emissions. The majority of these emissions come from burning coal, oil, or gas to produce steam, hot water, and hot air for processes such as dyeing, bleaching, drying, setting, or fabric finishing.
According to GEI (2024), thermal energy accounts for over 50% of a textile factory’s total energy demand, and approximately 25-30% of energy is lost during steam generation and transmission. This is a critical bottleneck that makes it difficult for the industry to reduce emissions if it continues to rely on fossil fuels. Focusing on clean energy heating in textile production is thus essential.
Distribution of electricity and thermal energy in a synthetic textile factory (excerpt from GEI study, 2024)
The spinning stage consumes the largest share of electrical energy (41%), followed by weaving and pre-weaving (18%). Meanwhile, wet processing stages such as preparation (desizing, bleaching, etc.), dyeing/printing, and finishing account for the majority of thermal energy consumption (50%). Additionally, a significant amount of thermal energy is lost during steam generation and distribution (35%).
Most steam is used in wet processing stages, thus, the electrification of heating systems in wet processing holds immense potential for reducing fossil fuel use and cutting greenhouse gas (GHG) emissions in the textile industry. Replacing fossil fuel-based boilers with electric technology helps eliminate on-site emissions and increases energy efficiency by avoiding heat loss. This approach directly addresses textile industry emissions.
Four Feasible Electrification Pathways in the Textile Industry
The report “Electrification of Heating in the Textile Industry” (GEI, 2024) provides a detailed analysis of four main electrification technologies applicable to the textile sector:
- Industrial Heat Pumps – particularly effective for wet processes such as dyeing, washing, and bleaching. These electric heat pumps in textile production offer significant efficiency gains.
- Electric Steam Boilers – replacing coal or gas-fired boilers.
- Electric Thermal Oil Boilers – used for drying, setting, or finishing.
- Direct Electric Dryers, Stenters – applied to processes where direct electrical heating is possible.
Simulation results from the GEI (2024) study show that if all factories in China, Japan, and Taiwan switched to electrification, energy consumption would decrease by up to one-third, while CO₂ emissions would drop by 45-54% by 2050. This demonstrates the immense potential of electrification clean energy.
Notably, electrification technologies such as industrial heat pumps and electric steam boilers are fully commercialized, easy to install, and integrate into existing production lines – something many Vietnam textile factories can implement immediately.
However, the GEI study (2024) also emphasizes that electrification truly reduces emissions only when the electricity source comes from clean energy. When the grid still contains a large proportion of fossil fuels, the transition may not reduce emissions in the short term (until 2030).
“If factories electrify but still use grid electricity that is not green, the emission reduction effectiveness may be low or even temporarily increase. But if renewable energy electricity is used – through PPA or rooftop solar power – CO₂ emissions can decrease immediately,” an excerpt from the GEI (2024) report states.
The study indicates that when businesses purchase renewable electricity directly (DPPA) or install on-site solar power, CO₂ emissions decrease immediately from the time of transition, while energy costs also significantly reduce in the long term by avoiding fossil fuel price volatility. This highlights the importance of solar power in achieving sustainability.
Electrification truly reduces emissions only when the electricity source comes from clean energy
Vietnam: From Biomass Energy to Electrification Combined with Clean Energy
In Vietnam, many textile factories have transitioned from using coal to biomass (rice husk, compressed wood). However, according to the study “Electrifying the Textile and Apparel Sector in Vietnam” by WWF and H&M Group (2024), biomass is not a sustainable long-term solution due to several reasons:
- Bio-CO₂ emissions from biomass are still high (equivalent to coal when calculated over its lifecycle).
- Difficulty in tracing origin and risk of deforestation.
- Limited supply and volatile prices.
- Significant on-site air pollution.
WWF recommends that the Vietnam textile industry should transition directly from biomass to “electrification combined with renewable energy.” In H&M’s pilot factories in Vietnam, electric steam boilers and industrial heat pumps have demonstrated the ability to reduce 50-100% of CO₂ emissions, improve the working environment, and reduce operational risks.
Particularly, when combining electrification with solar power or DPPA, production costs become more competitive than biomass, while also helping businesses meet the stringent requirements of international supply chains (Zara, H&M, Patagonia, etc.). This commitment to renewable energy ensures sustainable development.
Electrification with Clean Energy – The Fast Track to Net Zero for the Textile Industry
The transition to electrification with clean energy is not merely a technical solution but also a sustainable economic and environmental strategy for the textile industry in Vietnam and the wider region. As renewable electricity becomes increasingly affordable, electrification technology becomes more readily available, and policy mechanisms become clearer, this is the golden moment for businesses to act.
“Electrification with clean energy not only helps the textile industry reduce emissions but also enables businesses to achieve energy self-sufficiency, stabilize costs, and strengthen their position in the global supply chain.”
References:
- Hasanbeigi, A., & Zuberi, J. (2024). Electrification of heating in the textile industry: A techno-economic analysis for China, Japan, and Taiwan (Revision 1 – June 2024). Global Efficiency Intelligence, LLC. https://www.globalefficiencyintel.com/electrification-of-heating-in-the-textile-industry
- WWF & H&M Group. (2024). Electrifying the textile and apparel sector in Vietnam. World Wide Fund for Nature (WWF). Link
- Springer, C., & Hasanbeigi, A. (2025). Leveraging demand response to electrify heating in the textile industry in Southeast Asia. Global Efficiency Intelligence, LLC. https://www.globalefficiencyintel.com/leveraging-demand-response-to-electrify-heating-in-the-textile-industry-in-southeast-asia
