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The textile industry is now focusing on sustainable approaches due to environmental concerns. The study explores an innovative approach to sustainable production utilizing recycled cotton sourced from hard waste. The article examines the characteristics of rotor yarns (recycled) manufactured from seven different percentages of recycled and virgin cotton, ranging from 0% to 100% recycled cotton. The study investigates the influence of cotton (recycled) percentage on yarn characteristics and results indicate when recycled cotton percentage in yarn increases, irregularity (CVm%), hairiness (H), and imperfections index (IPI/km) of yarns increase but strength and elongation% decrease. The study focuses on reducing the environmental issues of denim production by incorporating sustainable recycled cotton. Statistical analysis (Pearson correlation) confirms significant correlations (relationship) between recycled cotton proportion and yarn characteristics. The rotor yarns were tested in an air-jet weaving machine for denim production and found suitable for commercial production. The study gives significant insights into manufacturing sustainable yarns incorporating recycled fibres, focusing on environmental issues.

Consumer preferences for comfortable and well-fitting clothing have led to an increased demand for yarns (elastic) in denim fabric production. The study focuses on the manufacture of yarns (dual core) with various core components including T400® (Polyethylene terephthalate) / poly trimethylene terephthalate), PBT (Polybutylene terephthalate), Polyester (PES), and elastane (Lycra®) and their impact on denim fabric properties. The study involves the production of Ne 18/1 yarns (dual core) using an adjusted spinning method (ring) with elastane and different filaments in the core and additionally, twill (3/1 ‘Z’) fabric (denim) is manufactured using those yarns, and then fabric and yarn characteristics are evaluated. The results show significant variations in fabric and yarn characteristics based on the type of core material used. The yarn properties, such as the neps (+200), strength, thin place (-50), hairiness, elongation %, unevenness %, and thick place (+50) of yarns (dual core) are affected by the selection of filament. Fabric properties like weight, elasticity %, strength (tensile), strength (tearing), shrinkage %, and stiffness exhibit differences depending on the core filament. The statistical analysis employs one-way ANOVA to investigate the significance of differences in yarn and fabric properties within various core materials. The outcomes of this experimental work contribute valuable understandings of the production of yarns (dual core) with several filaments for enhancing fabric (denim) performance.

Cotton and polyester fiber blends are commonly used to improve the aesthetic features of finished items. The denim industry’s growing need for polyester fiber aids in analyzing the performance of denim fabrics woven from rigid and stretched weft yarn combined with cotton and polyester. This study evaluates the weight, dimensional changes, stiffness, tensile and tearing strength, stretch, and comfort properties of denim fabric woven from cotton and polyester in various blended ratios. Here, Ne 14/1 (42 tex) 100% cotton warp yarn and Ne 18/1 (33 tex) weft yarns, consisting of 100% cotton, 75/25, 50/50, and 25/75 cotton/polyester (CO/PES) blends, as well as 100% polyester, were used to produce 3/1 Z twill denim fabric. The weft yarns were categorized into three groups: rigid, core-spun, and dual-core-spun yarns. Experimental results showed a higher polyester content in weft yarn, and denim fabrics’ tensile and tearing strength was improved, whereas fabrics’ weight loss, dimensional changes, and stretch properties were reduced. Furthermore, different statistical analyses were conducted to evaluate the type of weft yarn and blending ratio interaction and correlation with fabric properties. Additionally, a regression model was developed with the weft yarn type and blending ratio as independent variables to predict the fabric properties.

Denim fabrics are one of the important research fields in the textile industry. Super stretch denim fabrics that have more than 30% elasticity are among the hottest trends in denim fabrics recently. The entire process chain, from raw material to finished product, must be considered when developing fabrics with high stretch values. Previously, only 100% cotton yarn was used in the denim industry; however, some new generation yarn types are currently being used. Different multi-component core-spun yarns were produced and used as a weft yarn in five different denim fabrics. The study aimed to investigate the influence of fiber types used as core (EL: elastane, PBT: polybutylene terephthalate, T400®: PET/PTT) or as wrap fibers (cotton, modal, EME: Elastomeric multi ester) into the new developed core-spun yarns, on the stretch properties of denim fabrics. Experimental and statistical results show that fiber types used as core/wrappers in the multi-component weft yarns significantly affect all stretch properties of denim fabrics. Fabrics composed of weft yarn with the EL+T400® in the core and EME/CO in the wrapper gave the best results in stretch properties.

Elastic structures are opted in denim fabrics to increase elasticity and recovery properties of fabrics as well as comfort properties. In this study, performance properties of denim fabrics were evaluated comparatively as tensile strength, tearing strength, air permeability, mass change, dimensional stability, seam slippage, fabric growth, and stretchability. 100% cotton, core-spun and dual-core spun yarns (Ne 16/1) used at weft direction of denim fabrics. 100% cotton ring spun yarns (Ne 13.5/1) were used as warp yarns at all produced three denim fabrics. All the test results were measured numerically and evaluated statistically with one-way analysis of variance (ANOVA). There was significant difference found among fabrics for the variation of weft yarn structures from the statistical evaluation. The impact of varying washing processes on the stretch and growth (%) of denim fabrics was also revealed. Core-spun yarn containing denim fabric showed more growth and stretch percentage in all forms of washing processes. It was also found that packing density of yarns had a significant effect on air permeability of fabrics.

Worldwide yarn diversity in terms of structure and properties has increased in recent years. Especially composite yarns produced by multiple components have become very preferable in both weaving and knitting sectors. Among these yarns, core and dual core-spun yarn are more prominent in some areas due to their particular performance. In this study, the structure and properties of plain, elastane cored, and elastane + filament cored composite yarns, which were spun by using cotton as sheath fibers, are comparatively investigated. With a constant Ne 16/1 linear density, a carded yarn production line with modified ring-spinning system was used to produce the composite samples using 5.56% elastane ratio for both and 13.79% polybutylene terephthalate (PBT) ratio for dual core. It was observed that the strength of the composite yarns decreased, while the elongation values at the time of breaking tended to increase. There was some deterioration in transition from plain yarn to dual core composite yarn in terms of unevenness and yarn defects, while some improvement was observed in terms of yarn hairiness. In order to dwell on the causes of this situation, the surface and cross-sectional images of the yarns were also studied.