Towards circular denim: mechanical and comfort analysis of fabrics made from pre and post consumer recycled cotton waste

Conventional denim manufacturing processes pose an environmental burden, mainly due to their heavy dependence on virgin cotton, which has intensified efforts to find sustainable alternatives in the textile industry. This study investigates the mechanical and comfort properties of denim fabrics made from Pre-and Post consumer derived recycled cotton fibers. Denim fabrics were ready, such as untreated and treated (desized and scoured) virgin cotton, pre-consumer recycling cotton and post-consumer recycling cotton with yarn count ranging between 9 and 10 Ne. Subjective and objective analysis was used to analyze and evaluate mechanical and comfort properties such as tensile/tear strength, hand feels/softness tests, moisture management, air permeability and thermal conductivity. The findings showed that almost all fabrics produced using the treated pre-consumer cotton recycling process have the same mechanical and comfort characteristics as those of virgin cotton fabrics. On the other hand, recycled fabrics were less strong and felt less good, particularly in their untreated state, following consumer use. It is interesting to note that there were significant washing and pre-treatment of all types of fibers. The results indicate that the use of mechanically recycled cotton is likely to be a valid and sustainable substitute of virgin cotton in the denim manufacturing process. The study is a valuable addition to the evolution of the denim sector into an environmentally friendly one and promotes the introduction of the principles of the circular economy into the denim value chain.