Hong Kong based Crystal Group, one of Asia's largest garment manufacturers, has updated just-style on the latest steps being taken by the company to boost the sustainability of its operations.

Its Yida denim factory is on a long-term mission to improve the energy, water, waste, material usage, air quality and noise at its facility in China. But its ultimate goal is to send zero waste to landfill.

The facility says it has cut more then 1,872 tonnes of waste in just one year through waste management initiatives that include joint projects with suppliers to recycle thread cones, marker paper cones, chemical barrels and printer cartridges.

And to suit different production processes and product types it has adopted Lego-like sectional furniture that can be re-configured and re-used for everything from holding cut panels, semi-finished and finished products, through to stations for inspection and packaging.

Installation of an SAP ERP system across the whole production cycle has also helped reduce paper use by 90%, the company says.

Located at Zhong Shan in China's Pearl River Delta, Yida was set up in 2005 and makes 1m pairs of jeans a month for Levis, Gap, Target and JC Penney, as well as the Asian market. The company is the second-largest bottoms exporter in the People's Republic of China, and has a 4% share of the US jeans market.