Sustainable valorization of cotton fiber air suction waste: high-quality and functional fabric production with various fiber types

Abstract

This study was aimed to examine the properties of yarn and fabric produced by mixing the cotton air suction fiber wastes obtained from spinning mills with different fibres. This would help to investigate the possibility of producing high-quality recycled products. The aim was also to determine how different fibres affect the quality of recycled products, and to investigate the potential for product diversity. In the study, different fibers such as Tence^TM, Promodal, viscose, polyester, which are widely used in textile products, were preferred due to their positive properties in terms of fabric performance and comfort, as well as Outlast and super absorbent fiber (SAP, obtained from super absorbent polymer (C₃H₃NaO₂)n)) were used. These fibers were blended with cotton air suction waste fiber generated during ring spun yarn production at a ratio of 10%. Ne 20/1 carded ring spun yarns were produced using a conventional ring spinning machine. Accordingly, the blend compositions of the yarn consisted of 80% virgin cotton, 10% cotton air suction waste fiber, and 10% different fibers. Yarn properties and the performance, comfort and dyeing properties of the fabrics knitted from these blended yarns were analysed. The results showed that the fabric’s properties changed based on the type of fiber in the blend, and sometimes better results were achieved compared to the 100% virgin cotton reference fabric. Tencel-blended recycled fabrics yielded bursting strength values 26% higher before pre-treatment and 0.6% higher after pre-treatment than the reference fabric. Almost all blended recycled fabrics had a similar pilling tendency to 100% virgin cotton fabrics. Mass losses after 10,000 abrasion cycles were 92%, 12.5% and 6.7% lower for Promodal, viscose and polyester blended recycled fabrics, respectively. Compared to the 100% virgin cotton fabrics, blending with SAP- and cellulosic fiber-containing fibers can provide better breathability property in recycled compositions. Recycled fabrics containing viscose and SAP fibers showed the highest absorption, 56–58% higher than 100% virgin cotton fabric. Despite the low blending ratios, Tencel, SAP, and polyester fibers improved moisture management by promoting quick absorption, directional transport, and fast drying. SAP- and Promodal-containing recycled fabrics allowed more water vapor transmission, and polyester- and Promodal-blended recycled fabrics had the lowest thermal resistance. In spite of the different fibres in the recycled yarns blended with cotton and other fibers, a single-stage dyeing process achieved desired colour and colour fastness instead of multi-stage dyeing. This single-step dyeing process resulted in the desired colour values and colour fastness. After 10 washings, the recycled fabrics containing SAP and Outlast fibers provided the highest colour. In light of all these findings, it was concluded that selecting the right fibres for recycled fibre blends will help to achieve the desired properties and produce high-quality recycled products. Blending of recycled fibers with any kind of virgin fibres can be a solution to striking the right balance between quality and sustainability by maximizing waste utilization and reducing the need for virgin raw materials.