In the textile supply chain, the apparel manufacturing industry heavily relies on energy consumption (EC), contributing to greenhouse gas emissions. Understanding and optimizing energy usage in apparel manufacturing is crucial for sustainable and energy-efficient manufacturing. The EC in the industrial sewing operations is directly linked with sewing parameters, including fabric seam length, standard sewing speed, and stitching time. In general, the carbon footprint of an apparel industry is measured by considering the standard minute value (SMV) and specific energy consumption (SEC). However, these metrics include non-productive time and do not accurately measure actual EC or assess the industry’s carbon footprint. To address these limitations, this case study tackles this technical issue by calculating the stitching time of an industrial sewing machine based on its actual EC derived from the sewing machine’s motor power. This study employs EC modeling for industrial sewing parameters, including fabric seam length, standard sewing speed, and stitching time. This proposed model utilizes real-time data collected during the garment-making process, including fabric spreading, cutting, sewing, and ironing. The study allocates eleven sewing machines for a specific garment style to stitch a basic knit fabric t-shirt. The total EC for the entire garment-making (t-shirt) process at a single line is 0.1052 kWh, equivalent to 59.97 g of CO2 emissions (Bangladesh’s CO2/kWh emission factor). This study explores that a direct-drive servo motor consumes approximately five times less than its maximum motor load power, making it more energy-efficient than other sewing machines. Therefore, this study demonstrates the effectiveness of EC modeling by incorporating industrial sewing parameters and selecting energy-efficient sewing machines to reduce carbon footprints and enhance environmental sustainability in the apparel manufacturing industry.