Recycled fibers from pre- and post-consumer textile waste as blend constituents in manufacturing 100% cotton yarns in ring spinning: A sustainable and eco-friendly approach

The usage of recycled fibers has achieved enormous importance in the textile sector due to growing environmental awareness, legal requirements for more sustainability and the cost of raw materials. Recycled cotton fibers derived from mechanical shredding of textile waste possess lower quality values and therefore they are spun through blending with other fibers in rotor spinning system for the production of coarse yarns (10–20 Ne) to make denim, towel and home furnishing. Owing to low fiber migration, rotor yarns require high twist during spinning which makes them stiffer and poorly moisture absorbent. Rotor yarns also feel harsh in skin contact due to the presence of wrapper fibers in the yarn surface. Intending to make knit top garments like T-shirts and polo shirts, apparel manufacturers nowadays demand recycled fiber-contained soft and high moisture absorbent yarn that can be produced in ring spinning system. In the current endeavor, cotton fibers reclaimed from pre- and post-consumer textile waste were blended with virgin cotton and soft-twisted 30 Ne yarns were manufactured in ring spinning frame on an industrial scale in a spinning mill. A thorough analysis of the structure and properties of the yarns revealed that up to 25% recycled cotton fibers can be used as an alternative to virgin cotton to manufacture medium count (30 Ne) yarn in ring spinning suitable to produce knit top garments.