Textile industries are now focusing on sustainable issues in manufacturing operations to save the environment. The study focuses on the use of cotton fibers (recycled) sourced from fabric (knitted) waste (pre-consumer) to manufacture elastic yarn (dual-core) for denim fabric. The study involves the production of yarns (dual-core) using a redesigned ring spinning method with different elastomeric components, including T400® (Polyethylene terephthalate)/Polytrimethylene terephthalate), Polybutylene terephthalate (PBT), Polyester (PES), Lycra® (elastane), virgin cotton and cotton (recycled) fiber. The study investigates various yarn (Ne 18/1) characteristics such as strength, IPI (imperfection index), elongation %, unevenness %, and hairiness. It is noticed that the elongation and strength of recycled yarn (double core) are lower and IPI (Imperfection index), unevenness %, and hairiness values are higher than 100 % cotton (virgin) yarn (double core). One-way ANOVA (statistical analysis) is employed to assess the significance of differences among yarns manufactured from various core materials and found significant variation for all characteristics. Additionally, the article introduces the MOORA (multi-objective optimization based on ratio analysis) technique as a decision-making tool to determine the best yarn among three alternatives (PES yarn, PBT yarn, and T400 yarn) based on their properties, considering attributes and finding T400 filament containing yarn as the best option. The study introduces a sustainable approach using recycled cotton in yarn (double core) production and employs decision-making tools to assess and rank the performance of different yarn alternatives.

The spinning industry makes a major contribution to environmental pollution due to the excessive use of natural assets and the generation of remarkable amounts of waste during manufacturing processes. Now, the spinning industries are concentrating on sustainable activities due to environmental issues. While textile recycling efforts have been widely explored, the utilization of soft waste (process waste) in yarn production remains underexplored. This study addresses this gap by investigating a sustainable approach incorporating soft waste into producing sustainable yarn using the ring-spinning technique. The research explores the properties of yarns manufactured from a blend of virgin cotton and soft waste, and 100% virgin cotton yarn is produced for comparison. The results indicate that incorporating soft waste leads to an increase in CVm% (13 vs. 11), hairiness (6.9 vs. 5.1), and IPI (165 vs. 125) compared to virgin cotton yarn. However, the elongation percentage (7.1% vs. 8%) and tensile strength (12.6 cN/tex vs. 16.2 cN/tex) showed a reduction, highlighting potential trade-offs in mechanical properties. The statistical analysis applies one-way ANOVA to evaluate the significance of variations in yarn characteristics made from the mixture of soft waste + virgin cotton and only virgin cotton. The manufactured yarns were examined in a modern weaving machine as weft yarn for fabric (denim) manufacturing and found to be perfect for normal operation. The article focuses on reducing negative impacts on the fabric (denim) manufacturing environment by incorporating soft waste to produce sustainable yarn. This research provides important insights into the production of sustainable yarns, focusing on environmental concerns.

Elastane fibers, in particular, have gained an important share in the production of elastic yarn. This research aims to evaluate innovative methods for developing hybrid yarns (dual core) by integrating core elements in various configurations to show the influence of different core-inserting techniques on yarn characteristics. The research developed a modified pulley (W-grooved roller) to insert core elements side by side along with the existing method during the yarn manufacturing process. Ne 16/1 yarn (dual core) was manufactured using five different core inserting techniques with cotton roving, polybutylene terephthalate (PBT), and elastane (Lycra®). The characteristics of the produced yarns were analyzed using standard testing methods. Statistical analysis was performed to determine significant variations in yarn properties using one-way MANOVA and the MOORA method was employed to determine the most suitable yarn configuration. The results indicate that yarn manufactured by inserting core components side by side significantly enhances the expected characteristics of hybrid yarns. Yarns manufactured by inserting core components side by side show higher strength, elongation, and lower hairiness values. This research introduces a novel technique for producing dual-core yarns by side-by-side insertion of core elements contributing to the development of innovative hybrid yarns.

Stretchable yarns (double core) fulfill consumer requirements for comfortable clothing with a flexible structure. The study focuses on utilizing various methods and filaments in yarn production and their effect on fabric characteristics. The experimental study includes the manufacturing of Ne 18/1 yarn (dual core) by three different methods: Invista® method, Texturing/Intermingling method, and Elasto twist method (Hamel twist and cover method) for ‘Z’ and ‘S’ twist direction using various filaments and properties of the developed yarns are measured using standard methods. Additionally, 3/1 ‘Z’ twill denim fabric was manufactured using this manufactured yarn, and fabric properties were evaluated. The impact of production method and filament type on these developed yarns and fabrics properties is analyzed using Two-way ANOVA and it is concluded that the filament type and production technique have a meaningful impact on yarns and fabrics properties. This comparative analysis provides valuable information and highlights the significance of filament type and production method in achieving desired properties.

Integrating synthetic fibers into yarn manufacturing has revolutionized the development of stretchable fabrics, which have become essential in the textile industry. This research explores the development of Siro-spun dual-core yarns with elastane and PBT (polybutylene terephthalate) as core materials, alongside cotton as the sheath material, using a modified W-grooved roller system. The study aims to evaluate the impact of core material feeding techniques on the properties of the produced yarns. Five different samples were created using several feeding techniques, and their properties were investigated using standard testing methods and statistical tools such as MANOVA. The MOORA (Multi-Objective Optimization by Ratio Analysis) method was also employed to rank the yarn samples based on their overall criteria across multiple quality performances. The results revealed that yarns produced using the modified W-grooved roller exhibited superior mechanical (elongation and strength) and quality properties (hairiness, unevenness, and imperfections) compared to those produced using traditional methods. This comparative study demonstrates the potential of the modified W-grooved roller to optimize yarn performance, offering innovative solutions for stretchable yarn production and meeting the growing demands of the textile market.

Hybrid yarns combine the benefits of different fibers, enhancing strength, elasticity, and comfort, making them highly suitable for advanced textile and apparel applications. This study develops tri-core spun yarns using various core material configurations and spinning techniques, including texturing and Hamel twisting methods, to enhance the performance of denim fabrics. Yarns were manufactured with a modified (adjusted) ring-spinning system incorporating T400 ^® (PET-polyethylene terephthalate/PTT-polytrimethylene terephthalate) and Lycra ^® as core elements, with cotton as the sheath. The developed tri-core yarns were used as weft in 3/1 Z twill denim fabrics woven with indigo-dyed cotton warps under standardized conditions on a Rapier weaving machine (Picanol OptiMax-i). The results indicate that tri-core spun yarns significantly improve overall properties, particularly those produced using the Hamel twisting method. Statistical analysis (one-way MANOVA) confirmed significant differences among yarn and fabric properties. The Multi-Objective Optimization by Ratio Analysis (MOORA) method identified the most suitable fabric variant, with TC-5 yarn (The core components (filament and lycra ^® ) are combined with the Hamel twisting method, and the Lycra ^® is used as another core element), demonstrating optimal performance. This study provides valuable insights into the potential of tri-core spun yarns for high-performance denim and industrial applications.