Melt Spinning Process Optimization of Polyethylene Terephthalate Fiber Structure and Properties from Tetron Cotton Knitted Fabric

Polyester/cotton fabrics with different proportions of Tetron Cotton, TC (35% Cotton/65% PET), and Chief Value Cotton, CVC (60% Cotton/40% PET), were investigated by removing the cotton component under various phosphoric acidic conditions including the use of cellulase enzymes. The remaining polyethylene terephthalate (PET) component was spun using the melt spinning method. Only 85% H(3)PO(4)-Enz_TC could be spun into consistent filament fibers. The effects of Acid-Enz TC (obtained from a powder preparation of 85% H(3)PO(4)-Enz_TC) at different weight amounts (1, 2, 5, and 10 %wt) blending with WF-rPET powder prepared by white recycled polyester fabric were evaluated for fiber spinnability at different winding speeds of 1000 and 1500 m/min. The results revealed that recycled PET fiber spun by adding Acid-Enz_TC up to 10 %wt gave uniformly distributed filament fibers. A comparative study of the physical, thermal, and mechanical properties also investigated the relationship between the effect of Acid-Enz_TC and the structure of the obtained fibers. Acid-Enz_TC:WF-rPET (5:95) was the optimal ratio. The thermal values were analyzed by DSC and TGA and crystallinity was analyzed by XRD, with mechanical strength closed to 100% WF-rPET. The FTIR analysis of the functional groups showed the removal of cotton from the blended fabrics. Other factors such as the Acid-Enz_TC component in WF-rPET, extraction conditions, purity, thermal, chemical, and exposure experiences also affected the formability and properties of recycled PET made from non-single-component raw materials. This study advanced the understanding of recycling PET from TC fabrics by strategically removing cotton from polyester–cotton blends and then recycling using controlled conditions and processes via the melt spinning method.