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<p>This study demonstrates the industry-scale sustainable valorization of winding machine-generated cotton hardwaste through its conversion into recycled ring-spun yarns. Compared to virgin cotton, recycled fibers exhibit shorter lengths (25.34 vs. 33.27&#xa0;mm), higher short fiber content (18.78% vs. 5.56%), and increased neps (468 vs. 346 cnt/g), leading to greater yarn hairiness (7.92 vs. 5.85) and reduced strength. However, blending with virgin cotton significantly improves yarn tenacity and reduces defects. We also conducted ANOVA analysis and confirmed significant differences in yarn quality parameters (e.g., unevenness, imperfections, hairiness) among hardwaste-derived, virgin, and blended yarns. While 100% hardwaste-derived recycled yarns show inferior tensile strength and elongation (4.2%), optimized blends (e.g., 25:75 recycled/virgin) achieved a comparable quality to that of virgin cotton yarns. To verify manufacturability, single-jersey fabrics were knitted from the optimal blends on standard equipment without process modifications and evaluated only by visual/tactile inspection. Our cost analysis showed that leveraging hardwaste could save up to 44.3% in raw materials cost, making it lucrative for industries. This work enables sustainable yarn production without process modifications, balancing quality and circular economy goals.</p> Graphical Abstract <p></p>

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Industry-Scale Production of Sustainable 100% Cotton Yarn by Recycling Hardwaste in Ring Spinning

  • 期刊论文

  • 发表日期：

    2026年1月3日

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  • Prosenjit Sen,
  • Ashfaqul Hoque Khadem,
  • Habibur Rahman Anik,
  • Md. Rubel Khan,
  • Tanjina Riya,
  • Md. Mazbah Uddin,
  • Shariful Islam Tushar,
  • Priyanka Sarkar,
  • Suraj Sharma

摘要

This study demonstrates the industry-scale sustainable valorization of winding machine-generated cotton hardwaste through its conversion into recycled ring-spun yarns. Compared to virgin cotton, recycled fibers exhibit shorter lengths (25.34 vs. 33.27 mm), higher short fiber content (18.78% vs. 5.56%), and increased neps (468 vs. 346 cnt/g), leading to greater yarn hairiness (7.92 vs. 5.85) and reduced strength. However, blending with virgin cotton significantly improves yarn tenacity and reduces defects. We also conducted ANOVA analysis and confirmed significant differences in yarn quality parameters (e.g., unevenness, imperfections, hairiness) among hardwaste-derived, virgin, and blended yarns. While 100% hardwaste-derived recycled yarns show inferior tensile strength and elongation (4.2%), optimized blends (e.g., 25:75 recycled/virgin) achieved a comparable quality to that of virgin cotton yarns. To verify manufacturability, single-jersey fabrics were knitted from the optimal blends on standard equipment without process modifications and evaluated only by visual/tactile inspection. Our cost analysis showed that leveraging hardwaste could save up to 44.3% in raw materials cost, making it lucrative for industries. This work enables sustainable yarn production without process modifications, balancing quality and circular economy goals.

Graphical Abstract