Investigating the Ideal Combination of Virgin Cotton Fibre Length with Recycled Fibre for Better Yarn Quality

This study examines the effects of blending virgin cotton fibres of selected lengths with a fixed percentage of recycled fibres on yarn quality. By choosing three different lengths of virgin cotton fibres and incorporating 20% recycled fibre, we investigate the resultant yarn properties through detailed statistical analysis. Our research identifies significant enhancements in yarn quality with increased virgin fibre length, offering new insights into effective fibre blending strategies. This investigation supports the textile industry in refining fibre blend ratios for improved yarn qualities while advocating for sustainable practices through the utilization of recycled fibres. It sets the stage for future exploration aimed at optimizing the balance between virgin and recycled fibres to achieve superior yarn characteristics


INTRODUCTION
The optimal blending of virgin cotton fibre length with recycled fibre holds paramount importance in achieving high-quality yarn within the textile industry.The profound impact of fibre length and its associated parameters on cotton fibre quality cannot be overstated.Variability in length and characteristics within fibres from the same cotton cultivar annually at a given location is welldocumented [1].A reduction in fibre length has been identified as a factor adversely affecting yarn strength and introducing issues such as hairiness, thinness, thickness, and neps, contributing to overall yarn imperfections.Yarns derived from shorter fibres exhibit negative effects on tenacity, hairiness, and imperfections [2].Additionally, the sustainable aspects of utilizing recycled fibres enhance yarn quality, bringing unique characteristics to the blend that influence yarn properties alongside virgin cotton fibre length [14].The distribution of variations in fibre length plays a crucial role in predicting yarn properties; an increase in yarn linear density leads to increased hairiness, and the inclusion of https://doi.org/10.31881/TLR.2024.009recycled fibres introduces specific considerations in this context [3].fibre length significantly influences hairiness, with longer fibres associated with reduced hairiness.Conversely, an increase in short-fibre percentage results in higher hairiness.The quantity of short cotton fibres in a sample is vital for affecting yarn production efficiency [4][5][6].Short fibre content directly impacts the quality of cotton yarns, contributing to lower tenacity and evenness, higher imperfections, elevated hairiness, and reduced spinning efficiency [7,8].Standards for measuring short fibre content vary, with the American Standard Test Method (ASTM) [9] defining it as the percentage of fibres shorter than ½ inch (S.F.C.½″), while Chinese Standards Test Methods define it as fibres shorter than 16 mm (S.F.C.16 mm) [10].There is also a positive and highly significant association between yarn hairiness and short fibre content [11].
The short fibre index and fibre strength exert significant but opposing effects on yarn strength [12].
A positive correlation in fibre length changes across various phases [13].On average, fibre length increased during carding, breaker drawing, finisher drawing, and simplex stages but decreased during card mat and ring stages.The inclusion of recycled fibres adds a sustainable dimension to the investigation, offering insights into the synergistic effects of combining virgin cotton and recycled fibres on yarn quality.This study aims to explore the intricate dynamics of fibre length and its influence on yarn properties, with a specific focus on the interplay between virgin cotton fibre length and recycled fibre.

Fibre Characteristics and Preparation
Virgin cotton fibres and recycled fibres, with detailed characteristics outlined in Tables 1 and 2, were subjected to processing in spinning preparatory machines.The experimental design involved varying the ratio of virgin cotton to recycled fibres in the blending process.Slivers were produced according to the specified Virgin Cotton-Recovered fibre Mixing Ratio (Virgin Cotton-80%: Recycle fibre-20%).The recycled fibre used is 100% pure cotton, sourced from RBD Fibres Limited, located in Rupganj, Narayanganj, Bangladesh.Three distinct fibre lengths (26.65 mm, 28.25 mm, and 30.22 mm) were considered in the sliver production process.

Roving and Yarn Production
Following sliver production, a roving frame was employed to produce 0.8 Ne rovings with a count of 1.28 TM.Subsequently, a ring spinning frame was utilized to spin 30 Ne yarns with a count of 3.90 TM

Yarn Quality Testing
The initial assessment of yarn quality involved conducting unevenness tests using the Uster Tester 6.
Bundle strength analysis was then performed using a Lea strength tester machine, adhering to established standards.Yarn performance was calculated as the average of eight samples, each measured using the aforementioned yarn quality testing equipment.

Experimental Setup
The research experiment was conducted under the operational conditions of Mondol Spinning Mills Ltd.Three distinct mixing types were considered for fibre length analysis, each representing pure cotton with varying fibre lengths.The details of the three mixing ratios are presented in This method section outlines the comprehensive approach undertaken to investigate the influence of recovered fibre content in virgin cotton-recovered blends, encompassing fibre characteristics, processing steps, and yarn quality testing procedures.The experimental setup at Mondol Spinning Mills Ltd. ensured real-world applicability and relevance to industry practices.

Machinery used
A comprehensive array of machinery was employed to ensure the precision and efficiency of the experimental process.The machinery lineup included the following key components: Blow room, Carding, Breaker Drawing, Finisher Drawing, Simplex, and Ring Frame.Each machine played a crucial role in different stages of fibre processing and yarn production.
These machines were selected for their precision and reliability in the textile industry, ensuring the consistency of experimental conditions.The values and parameters of each machine are meticulously documented in Table 4, providing a comprehensive reference for the equipment used throughout the study.

RESULTS AND DISCUSSION
Raw cotton, carded sliver, breaker-drawn sliver, finisher-drawn sliver, and roving were sampled at each stage from raw cotton to the roving frame.Finally, all the samples underwent numerical testing using USTER AFIS PRO 2, as shown in Table 5.A detailed analysis presented in both Table 5 and Figure 1 delineates a further increase in fibre length from the breaker drawing to the roving frame for MT1, MT2, and MT3.This phenomenon underscores the significance of drawing action, specifically within the breaker draw frame, where the removal of trailing and leading hooks occurs.The orchestrated removal of these hooks through drawing action leads to an overall elevation in fibre length throughout the processing stages, contributing to the observed trends outlined in the data.
Moreover, Table 5 and Figure 2 highlight a concurrent reduction in short-fibre content.This reduction in short fibre content further aligns with the overall enhancement in fibre length, signifying the efficacy of the processing stages in promoting favourable textile characteristics.https://doi.org/10.31881/TLR.2024.009A notable trend observed in Figure 3 suggests that a higher proportion of high fibre length in the yarn corresponds to lower irregularity.MT1 and MT2 yarns exhibit the highest values in terms of irregularity, while MT3 follows a different pattern due to variations in fibre length between Virgin cotton and recovered fibre.
Finally, Figure 3 illustrates a decrease in the imperfection index with the incorporation of a higher fibre length portion in MT3 yarn.This reduction is attributed to the increased length and reduced short fibre content in the yarn, consolidating the imperfection parameters into a singular imperfection index term.Fibre length stands out as a key influencer in the strength of ring-spun yarns, a central theme reiterated in our research.Figure 6 visually conveys this relationship, demonstrating that an increase in fibre length corresponds directly to a higher Count Strength Product (CSP).

CONCLUSION
The length measurements obtained through USTER AFIS PRO2 consistently revealed a discernible pattern across all mixing types, showcasing an increase in fibre length and a simultaneous decrease in short fibre content during carding, breaker drawing, finisher drawing, and simplex processes.This observed trend underscores the pivotal role of fibre length in determining yarn strength, a factor critical to the overall robustness of the fabric.Furthermore, the length and distribution of fibres have far-reaching implications on fibre processing and subsequent yarn performance during mechanical processes such as weaving and knitting.The experimental results emphasize the significance of considering staple length concerning yarn quality, as shorter fibres correlate with a decline in yarn Count Strength Product (CSP), heightened hairiness, and increased imperfections.It is essential to recognize that yarn quality experiences a downturn with decreasing staple length, particularly impacting yarn strength, hairiness, and imperfections.Notably, the integration of recycled fibre forms an ideal combination with longer lengths, further enhancing the overall quality of the yarn.Therefore, https://doi.org/10.31881/TLR.2024.009Investigating the Ideal Combination of Virgin Cotton Fibre Length with Recycled Fibre for Better Yarn Quality Md.Mominul MOTIN 1 , Hasan Mazharul HAQ 2* , Ayub Nabi KHAN 3 , Md.Obaidur RAHMAN 1 , Md.Omar ALI4

Figure 1 .
Figure 1.Change in fibre length

Figure 2 .
Figure 2. Change in short fibre content

Figure 5 .
Figure 5. Elongation (mm) of the single yarn

Figure 6 .
Figure 6.CSP of the yarn

Table 1 .
Properties of Virgin cotton and recover fibres recorded from USTER HVI 1000

Table 2 .
Properties of Virgin cotton and recover fibres recorded from USTER AFIS Pro 2

Table 3 .
Mixing ratio of produced yarn

Table 5 .
Change in fibre length for different mixing types in different processing stages

Table 5 and
Figures 1 provide a comprehensive illustration of the observed increase in fibre length, attributable to the inherent variability in the raw material.Notably, the carding process played a crucial role in this augmentation by strategically removing short fibres as strips and dropping-1.Consequently, there was a notable enhancement in the average length of the fibres.

Table 6 .
Properties of produced yarn of different mixing types yarn characteristics, contributing valuable data to the broader understanding of yarn quality in textile production.https://doi.org/10.31881/TLR.2024.009