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Deadstock waste is a massive issue in the fashion industry, accounting for 15 % of textile production. 

This unused inventory, which often ends up in landfills or left in storage, costs brands, retailers, factories and mills approximately $152 billion per year, according to Stephanie Benedetto, the CEO of Queen of Raw.  These figures illustrate not only the significant cost burden but also a pressing environmental challenge. 

As fashion companies grapple with meeting profitability and sustainability goals, addressing waste is key. A major culprit is inefficient, outdated fabric estimation techniques. 

Traditionally, estimating the necessary amount of fabric for each order has been a delicate balancing act, relying heavily on the operator’s skill and experience. 

The operator’s ability to take into account all of the cutting, material and production volume constraints determines the efficiency of material consumption and compliance with the production schedule. This approach not only places immense pressure on the operator but also creates inefficiencies by tying critical production decisions to individual skill levels. 

This method also lacks the capacity to leverage data from past orders to accurately forecast production costs, meaning valuable insights are lost rather than integrated into future planning.

Another outdated approach to estimating fabric consumption relies on extrapolating consumption from smaller volume samples. This technique, however, fails to account for critical optimization factors, such as mixing orders on the same fabric, or cutting room constraints. 

Without the ability to adjust calculations for these considerations, companies miss out on efficiency improvements that could reduce costs and waste. 

Until now…

With the launch of Valia Fashion Estimate, which can be integrated into a company’s existing processes and IT infrastructure, fashion brands can  reduce reliance on hard-to-find skilled workers while achieving unprecedented accuracy in their fabric estimation processes. 

Leveraging the power of AI and the cloud, this intelligent digital platform enables fashion companies to take into account a vast range of fabric constraints and variables, enabling precise fabric consumption estimations and cost simulations. 

Valia Fashion Estimate offers a clear advantage to fashion brands and manufacturers by simplifying the complex estimation process and helping them achieve a leaner process with more predictable, optimized resource use. Its smarter calculations enable brands to not only reduce costs but also minimize fabric waste.

Valia Fashion Estimate also empowers manufacturers to create the most realistic simulations possible by taking into account a multitude of production constraints such as spreading, cutting, and offloading. With highly precise simulations, they can respond to RFQs faster, ensure consistent end-product quality, regardless of operator experience, and secure their margins.  

With fully automated fabric consumption calculations, fashion companies can handle smaller, more frequent and complex orders with greater agility and efficiency. This agility is critical in a fashion landscape where consumer preferences shift rapidly, and brands must keep up with demand without sacrificing quality or sustainability.

The fabric estimation process plays a pivotal role in profitability. 

Valia Fashion Estimate represents a significant leap forward for fashion companies. It empowers organizations to unlock efficiencies that were previously out of reach and achieve sustainability goals with more accurate fabric estimation methods.