Innovative Methods for Secondary Material Development in Mechanical Textile Recycling

Abstract

The textile and apparel industry generates significant waste, with only 14.7% of the 17 million tons produced in 2018 being recycled. Current mechanical recycling efforts often result in downcycled products and lack scalability for commercial viability. This research explored innovative methods for developing yarns and nonwoven fabrics using mechanically recycled fibers ("Respool fibers") to address these challenges. End-of-use 100% denim cotton and polyester fabrics were shredded into fibers and blended with new fibers at 65% and 85% recycled-to-new ratios. The fibers were processed into yarns and nonwoven fabrics, and their durability (tensile strength, elongation) and comfort (thickness, air permeability) properties were analyzed. Results showed that yarns with 65%, 85%, and 100% recycled polyester exhibited comparable tenacity, demonstrating potential for high recycled fiber content without sacrificing strength. Nonwoven fabrics with higher recycled content were more breathable, suggesting suitability for applications prioritizing air permeability. These findings advance circularity in textile production.