DESC:TECHNICAL FIELD
[001] The present invention relates to the field of textile recycling. More specifically, the present invention relates to a method for recycling textile waste material. The present invention further relates to a method for producing a fabric using the recycled fibre and the madeup thereof.

BACKGROUND OF THE INVENTION
[002] The fabric industry, essential for our everyday clothing and textiles, faces a significant challenge with the environmental impact of traditional production methods. In this regard, a primary source of fabric for the fabric industry is cotton cultivation. The cotton cultivation demands substantial water, chemical fertilizers, and pesticides. This not only puts a strain on natural resources but also contributes to rising costs and environmental concerns. Moreover, the textile manufacturing process generates substantial hard waste, leading to a considerable textile waste problem globally.
[003] Current practices in fabric manufacturing involve cultivating virgin cotton, which poses environmental challenges. Additionally, the fabric industry generates significant hard waste during various manufacturing steps, with only a fraction being reused or upcycled. Moreover, the heavy reliance on virgin cotton, coupled with the challenges of fluctuating cotton prices and weather-dependent yields, highlights the need for alternative approaches. Furthermore, the existing methods to manage hard waste often fall short of efficiently recycling and reusing materials. The substantial amount of textile waste ending up in landfills poses a serious environmental threat.
[004] Every year, around 92 million tons of textile waste is generated globally. And it is expected to increase to 134 million tons by 2030. 20% of the total waste generated is reused or upcycled and only less than 1% of textile waste generated is being recycled. Around 18.6 million tons textile waste is ended up in landfill annually and is expected to reach 150 million tons by 2050 if similar trend is followed. At present, only 800 to 1000 kg hard yarn waste is generated per day and 7.5 to 8.5 MT fabric hard waste is generated per day. Notably, on one hand the virgin cotton requires a lot of water and land for the cultivation thereof and on the other hand there are tons of hard cotton waste generated per day.
[005] While conventional methods provide many desirable properties such as sustainability, cost effective, use of waste cotton material, there is a desire to further increase the sustainable properties of a fabric. Furthermore, the existing techniques are also limited in terms of the number of materials that may be blended to obtain a fabric, thereby limiting the performance and characteristic of such fabrics.
[006] Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks associated with the conventional methods for manufacturing sustainable fabrics using recycled fibre.

SUMMARY OF THE INVENTION
[007] An aspect of the present invention is directed to a method for recycling a textile waste material. The method comprises collecting the textile waste material and cutting the collected textile waste material into a predefined length to obtain a cut textile waste material. Subsequently, passing the cut textile waste material through one or more opening rollers, and/or an air blowing unit to obtain opened fibres. The method also includes optionally carding the opened fibres to produce recycled fibres.
[008] In an embodiment, the textile waste material is a discarded or unused textile or fabric-based product, the textile waste material made from fibres selected from the group consisting of cotton, flax, hemp, wool, silk, asbestos, polyester, nylon, rayon, man-made fiber, cellulosic fiber, derivative of cellulosic fiber, acrylic, synthetic fiber, recycled synthetic fibre and/or natural fibre and/or man-made fibre, and combinations thereof.
[009] In another embodiment, the textile waste material is selected from the group consisting of yarn hard waste, open-end yarn hard waste, BS non-FRC waste, BS FRC waste, BS weaving hard waste, towel FRC waste, and towel weaving hard waste.
[010] In yet another embodiment, the pre-defined length ranges between 20 mm to 80 mm.
[011] In a further embodiment, the opened fibres contain open and separate fibres of the cut textile waste material.
[012] In still another embodiment, the step of passing the cut textile waste material through the one or more opening rollers and/or the air blowing unit reduces a number of hard ends to below 25%.
[013] In another embodiment, the step of carding further reduces the number of hard ends to less than 2%.
[014] Another aspect of the present invention is directed to a yarn comprising the above recycled fibre. The recycled fiber is characterized by: a mean micronaire (MIC) value ranges between 3.7 to 4.5, an upper half mean length (UHML) value ranges between 15.0 to 28.2, a uniformity index (UI%) ranges between 77 to 81, a specific fibre strength index (SFI) value ranges between 10 to 20, tensile strength ranges between 15-32, an elongation value ranges between 5 to 7, a yellowness index (+b) ranges between 9 to 10.4, and the number of hard ends is less than 2%.
[015] Yet another aspect of the present invention is directed to a method for producing a fabric. The method comprises obtaining the above yarn comprising at least 20 wt.% of the recycled fibre and weaving or tufting the yarn to produce the fabric.
[016] In an embodiment, the yarn is produced by feeding the recycled fibres to a blow room machine to obtain opened and loosened fibres, followed by carding the opened and loosened fibres in a carding machine to obtain a sliver containing the recycled fibres. The method also includes drawing the sliver in one or more drawing units, transferring the sliver to a speed frame unit to obtain a roving, and spinning the roving in a ring spinning unit or an open-end spinning unit to produce the yarn.
[017] In another embodiment, the yarn is obtained by feeding the recycled fibres to a blow room machine to obtain opened and loosened fibres, carding the opened and loosened fibres in a carding machine to obtain a sliver containing the recycled fibres, drawing the sliver in one or more drawing units, and feeding the sliver in a rotor or an air jet machine to obtain the yarn.
[018] In still another embodiment, the yarn is a single yarn or a double yarn or a multiplied yarn.
[019] In another embodiment, the sliver obtained from the one or more drawing units is optionally subjected to combing in a combing unit to remove shorter fibres and impurities from the sliver.
[020] In yet another embodiment, the recycled fibre is blended with one or more natural fibres, man-made fibres, cellulosic fibres, and/or synthetic fibres..
[021] In a further embodiment, the fabric is subjected to wet processing which includes one or more of the following steps: conditioning, washing, desizing, scouring, bleaching, dyeing, printing, and finishing.
[022] In a still further embodiment, the fabric is selected from the group consisting of a flat fabric, a terry fabric, tufted fabric, loop/cut loop, and derivatives thereof.
BRIEF DESCRIPTION OF FIGURES
[023] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates a flow chart depicting a method for recycling textile waste material in accordance with an embodiment of the invention.
Figure 2(a) illustrates a flow chart depicting a method for producing a fabric (flat or terry cloth) from a recycled fibre obtained in Figure 1 in accordance with an embodiment of the invention.
Figure 2(b) illustrates a flow chart depicting a method for producing a fabric (rug) from a recycled fibre obtained in Figure 1 in accordance with an embodiment of the invention.
Figure 3(a) illustrates a step of spinning using a single yarn ring spinning unit in accordance with an embodiment of the invention.
Figure 3(b) illustrates a step of spinning using a single yarn open-end spinning unit in accordance with an embodiment of the invention.
Figure 3(c) illustrates a step of spinning using a double yarn ring spinning unit in accordance with an embodiment of the invention.
Figure 3(d) illustrates a step of spinning using a double yarn open-end spinning unit in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION
[024] Various features and embodiments of the present invention here will be discernible from the following further description thereof, set out hereunder.
[025] The present invention broadly relates to recycling textile waste material. Embodiments of the present invention are directed towards a sustainable method of production of a fabric using recycled fibre that facilitates conservation of natural resources, reduces textile waste, and promotes eco-friendly practices in the textile industry.
[026] Accordingly, an aspect of the present invention relates to a method for recycling a textile waste material.
[027] The term "textile waste material" as used herein refers to any discarded or unused textile or fabric-based product, which may include remnants, cuttings, or end-of-life textiles. The textile waste material can originate from various sources such as manufacturing processes, post-consumer goods, pre-consumer or other textile-related activities.
[028] In an embodiment, the method comprises collecting the textile waste material as shown in Figure 1. The textile waste material comprises of natural fibres and/or synthetic fibres. As used herein, "natural fibres" encompass those obtained from botanical sources (e.g., cotton, flax, hemp), animal sources (e.g., wool, silk), and mineral sources (e.g., asbestos), wherein said fibres maintain their innate characteristics without substantial alteration or modification during the extraction and processing stages. "Synthetic or man-made fibres" as utilized herein, refer to fibres that are artificially produced through chemical or mechanical processes, wherein the raw materials used may include polymers, chemicals, or other non-natural substances. Such fibres are distinct from natural fibres and may include, but are not limited to, polyester, nylon, rayon, acrylic, and other fibres created through extrusion, spinning, or similar manufacturing methods. The synthetic fibres are engineered to possess specific characteristics such as durability, resistance, elasticity, and so forth.
[029] In another embodiment, the textile waste material comprises of natural cotton fibres. “Natural cotton fibres" as used herein refers to a soft, fluffy fibre obtained from the seeds of cotton plants. The natural cotton fibres are staple in textile production due to their natural properties, including breathability, absorbency, and comfort. In other words, the natural cotton fibres refer to cotton fibres that are obtained directly from the cotton plants.
[030] In yet another embodiment, the textile waste material comprises both the natural cotton fibres and the synthetic fibres.
[031] Accordingly, in an embodiment, the textile waste material is a discarded or unused textile or fabric-based product, the textile waste material made from fibres selected from the group consisting of cotton, flax, hemp, wool, silk, asbestos, polyester, nylon, rayon, man-made fiber, cellulosic fiber, derivative of cellulosic fiber, acrylic, synthetic fiber, recycled synthetic fibre and/or natural fibre and/or man-made fibre, and combinations thereof.
[032] In another embodiment, the textile waste material is selected from the group consisting of yarn hard waste, open-end yarn hard waste, BS non-FRC waste, BS FRC waste, BS weaving hard waste, towel FRC waste, and towel weaving hard waste. These are all types of hard yarn/fabric waste collected from 100% cotton article, or in an alternate embodiment blended article and sent for next process of cutting. Herein, BS refers to bedsheet and FRC refers to Fent Rags Chindi.
[033] The step of collecting involves gathering or sourcing the textile waste material which is a raw material or a discarded textile material to be used for recycling. It will be appreciated that the step of collection contributes to environmental conservation by repurposing the textile waste material. Moreover, the step of collection promotes the efficient utilization of both the natural cotton fibres and the synthetic fibres from the textile waste materials.
[034] As shown in Figure 1, the method further comprises cutting the collected textile waste material into a pre-defined length to obtain cut textile waste material. The pre-defined length ranges between 20 mm to 80 mm. The term "pre-defined length" as used herein refers to a specific and predetermined measurement that is established in advance for achieving uniformity in the subsequent processing steps of the method, ensuring consistency and quality in the resulting recycled fibre. The step of cutting is performed to standardize the length of the textile waste material, thus ensuring uniformity in subsequent processing steps of the method. Cutting is typically executed using a cutting tool designed to achieve the pre-defined length range. However, other cutting techniques known to a person skilled in the art are well within the purview of the present invention.
[035] Subsequently, the cut textile waste material is passed via at least one of: a plurality of opening rollers or an air blowing unit, to obtain opened fibres, as shown in Figure 1. The term " opening roller" as used herein refers to a mechanical device that is designed to open and separate fibres in the textile waste material. In this regard, the method employs the plurality of opening rollers that rotate at different speeds, exerting a beating action on the textile waste material passing through them. The step of passing enables opening the fibres of the cut textile waste material and preparing them for subsequent processing. Suitable opening rollers are known to the person skilled in the art.
[036] The term "air blowing unit" as used herein refers to a mechanism that utilizes controlled air currents to open and separate fibres in the cut textile waste material. The air blowing unit involves the directed application of air to the cut textile waste material, creating a gentle opening effect. In this regard, the cut textile waste material is fed through the plurality of opening rollers or subjected to the air blowing unit. In case of the plurality of opening rollers, the cut textile waste material moves through each of the plurality of rollers, experiencing a mechanical beating action that separates and opens the fibres. In case of air blowing unit, controlled air is applied to the cut textile waste material, achieving a gentle opening effect.
[037] In an embodiment, the step of passing the cut textile waste material through the one or more opening rollers and/or the air blowing unit reduces a number of hard ends to below 25%. This ensures the quality of the resulting recycled fibre.
[038] As shown in Figure 1, the opened fibres are optionally subjected to carding to reduce hard ends upto 2%. Herein, the term "carding" refers to the mechanical process of opening and cleaning fibres to create a web of fibres suitable for spinning into a yarn. Herein, the term “hard ends” refer to undesirable elements in the fibres that can affect the quality and texture of the final fabric. The hard ends are stiff or coarse portions of the fibres that need to be reduced or eliminated to enhance the overall feel and appearance of the fabric.
[039] During carding the opened fibres are subjected to a carding machine to perform a fibre level opening. Optionally, carding could be mild carding that involves removal of the hard ends present after the opening, which are reduced to less than 2%. Carding marks the end of recycling the textile waste material and therefore, the resulting fibre obtained is also known as recycled fibre.
[040] In an embodiment, the method comprises:
a. collecting the textile waste material;
b. cutting the collected textile waste material into the predefined length to obtain the cut textile waste material;
c. passing the cut textile waste material through one or more opening rollers and/or the air blowing unit to obtain the opened fibres; and
d. carding the opened fibres to produce the recycled fibres.
[041] In another embodiment, the method consists of:
a. collecting the textile waste material;
b. cutting the collected textile waste material into the predefined length to obtain the cut textile waste material;
c. passing the cut textile waste material through one or more opening rollers and/or the air blowing unit to obtain the opened fibres; and
d. optionally carding the opened fibres to produce the recycled fibres.
[042] The recycled fibre can be used as a raw material for manufacturing a yarn. The yarn can then be used to make a fabric using suitable techniques. The fabric, in turn, can be used to manufacture various textile products.
[043] The recycled fibre of the present invention has properties comparable, in fact similar to the virgin cotton fibre. Therefore, the method of the present invention results in recycled fibres which substantially reduce the water requirement for producing equal amounts of natural cotton fibre, drastically reduces the land (and associated) cost requirement for cultivation, and effectively utilizes the available waste for converting it to reusable fibre for making fabrics.
[044] Another aspect of the present invention relates to a yarn comprising the above recycled fibre. Accordingly, the embodiments pertaining to the recycled fibre are applicable here as well.
[045] In an embodiment, the recycled fiber is characterized in that: a mean micronaire (MIC) value ranges between 3.7 to 4.5, an upper half mean length (UHML) value ranges between 15.0 to 28.2, a uniformity index (UI%) ranges between 77 to 81, a specific fibre strength index (SFI) value ranges between 10 to 20, tensile strength ranges between 15-32, an elongation value ranges between 5 to 7, a yellowness index (+b) ranges between 9 to 10.4, and the number of hard ends is less than 2%. The properties of the yarn can be determined using suitable methods. For instance, strength of the single yarn is determined using ASTM D2256, yarn unevenness is determined using AST D1425, and yarn hairiness is determined using Uster Test. Unless specified otherwise, all fibre parameters presented herein are measured according to the industry standard testing practices.
[046] The yarn comprising the recycled fibre has been interchangeably referred as recycled yarn hereinbelow.
[047] Another aspect of the present invention relates to a method for producing a fabric using the above recycled fibre. Accordingly, the embodiments pertaining to the recycled fibre are applicable here as well.
[048] In an embodiment, the method comprises obtaining the yarn comprising at least 20 wt.% of the above recycled fibre, followed by weaving or tufting to produce the fabric.
[049] The term "fabric" as used herein refers to a flexible material produced by weaving, knitting, or non-woven together. The fabric encompasses various textile structures, including but not limited to flat fabrics (such as sheets and clothing) and three-dimensional products such as rugs or towels. The fabrics serve multiple purposes, providing both aesthetic and functional properties in various applications.
[050] In an embodiment, yarn made with 100% recycled fibre can be used for producing the fabric. Alternately, yarn containing blended fibres including at least 20% recycled fibre can be used for making the fabric. In an embodiment, the yarn count ranges between 3s Ne to 30s Ne in Open-end (OE) unit and 3s Ne to 60s Ne in ring spun unit.
[051] In an embodiment, virgin cotton fibres can be blended with the recycled fibre. Herein, the term virgin cotton fibres refer to new, unused cotton fibres obtained directly from the cotton plant. An example of the virgin cotton fibre is a fresh cotton harvest. In another embodiment, S-6 cotton (UHML > 28 mm) or any long staple cotton fibre is suitable for blending.
[052] In still another embodiment, virgin synthetic fibre can be blended with the recycled fibre. Herein, the term virgin synthetic fibre refers to unused synthetic fibres. For instance, the recycled fibres can be blended with synthetic fibre like recycled rayon (contain recycle pulp about 30% or more), recycled polyester, and recycled nylon.
[053] In yet another embodiment, a combination of the recycled fibre, virgin cotton fibre, and virgin synthetic fibre may be used for making the fabric.
[054] The variety of the recycled fibre variants allows for adaptability in fabric properties, catering to different applications. Moreover, blending with virgin fibres or synthetic fibres can enhance specific properties such as strength, texture, or other desired attributes. Beneficially, the method ensures that the resulting fabric can be tailored to meet specific needs by offering these different variants, whether in terms of sustainability, texture, or overall performance.
[055] The yarn may also include one or more of the following fibres: linen, hemp, kapok, nettle, bamboo, lyocell, viscose, polyester (sustainable or recycled), polylactic acid (PLA), polybutylene terephthalate (PBT), nylon, acrylic, and mixtures thereof. Further, the yarn may also include one or more of the following fibres: polyvinyl alcohol (PVA), wool, silk, co-polymer of polyester, bio-based compostable and biodegradable fibres, bio-based non-compostable and non-biodegradable fibres, non-bio-based compostable and biodegradable fibres, non-bio-based non-compostable and non-biodegradable fibres, and mixtures thereof. The choice of commonly used fibre for combining with the recycled fibre is known to the person skilled in the art and is well within the purview of the present invention.
[056] Further, blending may be carried out in a blow room machine and/or a drawing unit, as described hereinbelow.
[057] In an embodiment, the yarn is obtained as follows:
(a) feeding the recycled fibres to a blow room machine to obtain opened and loosened fibres,
(b) carding the opened and loosened fibres in a carding machine to obtain a sliver containing the recycled fibres,
(c) drawing the sliver in one or more drawing units,
(d) transferring the sliver to a speed frame unit to obtain a roving, and
(e) spinning the roving in a ring spinning unit or an open-end spinning unit to produce the yarn.
[058] The yarn includes a single yarn or a double yarn or a multiplied yarn. In an embodiment, the yarn for making the fabric is a single yarn obtained from a single yarn ring spinning unit as shown in Figure 3a. As shown, the recycled fibres are fed into the blow room machine, where they are opened and loosened using rollers with sharp teeth. This removes any clumps or tangles and prepares the recycled fibres for further processing. The opened fibres go through the carding machine, which aligns and straightens them in one direction. This creates a thin web of aligned fibres called a sliver. The sliver is fed into the draw frame, which stretches and thins it out further. This increases the uniformity and fineness of the recycled fibres. Optionally, the sliver is subjected to combing which removes shorter fibres and impurities from the sliver, resulting in smoother and stronger yarn. Another round of drawing further refines and thins the sliver, preparing it for the spinning stage. The sliver is now transferred to the speed frame, which converts it into a thicker and stronger strand called roving. This makes the spinning process on the ring frame more efficient. The roving is spun into the yarn on the ring frame. The ring and spindle twist and draw the fibres into a continuous thread, creating the final single yarn. The spun yarn is wound onto a bobbin for storage or further processing. The yarn is then finally steamed to remove snarls and more relaxed and stable final fibre product.
[059] In another embodiment, the yarn is a double yarn produced using a ring spinning unit with the recycled fibres for making the fabric as shown in Figure 3c. In this regard, the recycled fibres go through opening, carding, drawing, and optional combing as above. Further, the drawn recycled fibres are spun into single yarns on the ring frame. These single yarns are wound onto separate bobbins. Furthermore, the parallel winding combines and aligns two single yarns onto one bobbin. Finally, twisting further strengthens the double yarn by adding additional twist, creating a thicker and more robust final fabric. Thereafter, steaming finishes the process by removing snarls and stabilizing the yarn.
[060] In yet another embodiment, the yarn is obtained as follows:
(a) feeding the recycled fibres to a blow room machine to obtain opened and loosened fibres,
(b) carding the opened and loosened fibres in a carding machine to obtain a sliver containing the recycled fibres,
(c) drawing the sliver in one or more drawing units, and
(d) feeding the sliver in a rotor or an air jet machine to produce the yarn
[061] In an embodiment, the single yarn from recycled fibres in the open-end spinning unit may be used for making the fabric as shown in Figure 3b. Firstly, the recycled fibres are opened and aligned in the blow room and the carding machine. Optionally, the combing can further refine the recycled fibres. Then the draw frame thins and prepares the recycled fibres for the spinning. Instead of ring frames, the fibres directly go to the rotor or the air jet machine, which uses high speed to twist and draw them into yarn, bypassing roving, and speed frame stages. Finally, the spun yarn is wound onto a bobbin.
[062] In yet another embodiment, double yarn from the recycled fibres may be produced using an open-end spinning unit for making the fabric as shown in Figure 3d. Herein, the recycled fibres undergo initial opening, carding, and drawing similar to the single yarn open-end spinning technique. Two optional combing steps further refine the recycled fibres, leading to smoother and stronger yarn. Moreover, the rotor or air jet spinning directly converts the recycled fibres into the single yarn, which get wound onto the bobbins. Similar to the ring spinning unit, the parallel winding combines two single yarns onto one bobbin. Finally, twisting strengthens the doubled yarn, creating the sturdy fabric or the textile product.
[063] Herein, carding is performed using a carding unit or the carding machine that uses a series of rollers covered with card clothing to align the fibres and remove impurities. In this process, the card is run at a speed of 35 to 45 kg/hour, which is normally 15 to 25 % lesser speed then regular speed of the card. Carding ensures a more comfortable and aesthetically pleasing fabric, addressing the issue of the hard ends that may be present in the initial opened fibres.
[064] During the draw frame process, drafting is performed, and fibre is made more parallel and hooks are removed. In an embodiment, six slivers can be used and subjected to draft to make one. Combing is performed to remove short fibre. Further, speed frame is used to make roving which is the input material of ring frame. The ring frame is used to make single yarn in S or Z direction with a twist multiplier of 1.8 to 5. Optionally, 66% of the single yarn is twisted in a double yarn.
[065] A rotor is used to convert sliver to open end yarn using rotor with high speed. The air jet spinning is used to convert the sliver to open end yarn with high speed in Murata vortex spinning, Murata Jet Spinning and Rieter Air jet spinning. The winding is used to make bigger package. The steaming is used to remove the snarling and making the yarn relax and stable. Parallel winding is used to wind two yarns required for double yarn. The twisting is used to give required twist in the yarn.
[066] The method comprises spinning the recycled fibre, via the ring-spinning unit or open-end spinning unit, to form recycled yarn. The term "spinning" as used herein refers to the process of converting the recycled fibre into yarn by twisting them together. The step of spinning is crucial in creating the foundation for weaving or tufting the yarn into fabric. The quality of spinning directly influences the characteristics of the final fabric.
[067] Herein, the term "ring-spinning unit" refers to a traditional spinning system widely used in textile manufacturing. The ring spinning unit involves a series of machines where fibres are drawn, twisted, and wound onto a bobbin. The term "ring" comes from the rotating rings that guide the yarn formation during the method. Herein, the term "open-end spinning unit" refers to an alternative spinning technology. In the open-end spinning unit, the fibres are opened, twisted, and spun into the yarn directly without the need for a rotating spindle.
[068] The choice between the ring-spinning unit or the open-end spinning unit depends on factors such as the desired yarn characteristics, production efficiency, and specific manufacturing preferences. In this regard, the recycled fibre is fed into the ring-spinning unit, where the recycled fibre undergoes drafting, twisting, and winding processes. The recycled yarn is then wound onto a bobbin. Alternatively, in the open-end spinning unit, the recycled fibre is opened and formed into the recycled yarn directly without the use of a rotating spindle.
[069] The spinning step transforms the recycled fibre into the recycled yarn. The spinning process imparts strength, uniformity, and desired characteristics to the recycled yarn, ensuring it meets the specifications required for subsequent fabric production.
[070] In an embodiment, the recycled fiber is characterized in that: the mean micronaire (MIC) value ranges between 3.7 to 4.5, the upper half mean length (UHML) value ranges between 15.0 to 28.2, the uniformity index (UI%) ranges between 77 to 81, the specific fibre strength index (SFI) value ranges between 10 to 20, tensile strength ranges between 15-32, the elongation value ranges between 5 to 7, the yellowness index (+b) ranges between 9 to 10.4, and the number of hard ends is less than 2%. In this regard, the recycled yarn possesses specific characteristics, each defined by various parameters, ensuring quality and suitability for the fabric. Moreover, each parameter contributes to the overall performance and appearance of the fabric. The mean micronaire (mic) property represents the fineness of the fibres. The upper half mean length (UHML) indicates the length distribution of the fibres. The uniformity index (UI%) measures the uniformity of the fibre length. The specific fibre strength index (SFI) assesses the strength of the fibres. The tensile strength measures the resistance of the yarn to breaking. Elongation represents the stretchability of the yarn. Yellowness index (+b) measures the coloration of the yarn. The percentage of the hard ends indicate the presence of undesired elements in the yarn. The ranges for each parameter define acceptable limits, ensuring a balance of properties in the recycled yarn. The aforementioned parameters ensure that the recycled yarn meets quality standards consistent with the intended use.
[071] Subsequent to the spinning step, the recycled yarn is subjected to weaving or tufting to produce the fabric. The term "weaving" as used herein refers to a process of fabric production that involves interlacing two sets of yarn - the warp, and the weft, to create a woven fabric. The warp yarns run lengthwise, and the weft yarns run crosswise, forming a stable and structured textile. In this regard, the recycled yarn obtained from the spinning process is subjected to weaving, where the recycled yarn is threaded onto a loom. The loom facilitates the interlacing of the warp and the weft yarns, creating the woven fabric. The weaving imparts strength, structure, and durability to the fabric. The interlacing of the recycled yarns creates a cohesive textile that can be used for a wide range of applications, from clothing to household textiles. During the weaving the fabric is made in air jet loom and for terry cloth two beam warp sheet such as ground and Pile is used. And for the flat cloth one beam warp sheet is used. For terry cloth different GSM for 200 to 1800 in 3, 4, 6 pick terry and their derivatives in dobby / jacquard design and for flat fabric from 100 to 1000 GSM fabric made with pain, twill, satin, and their derivative in dobby/ jacquard design. Figure 2a illustrates the method for producing flat or terry cloth from the recycled fibre.
[072] Optionally, warping is performed before weaving of the yarn into the fabric. During the warping, a warp sheet is made for the loom. Moreover, a size is applied to enhance the weaveability properties, especially strength, lubrication, and binding properties. In flat cloth warp sheet and terry cloth ground the pickup 7% to 10% and for Pile sheet 3 to 5%.
[073] The term "tufting" as used herein refers to an alternative method of creating textiles, often used for producing rugs, carpets, and similar products. In tufting, the recycled yarn is stitched or punched through a base material, creating loops or tufts on one side and a smooth surface on the other. The recycled yarn is utilized in tufting by feeding it through a tufting unit. The tufting unit punctures the base material, creating loops or tufts on one side. The length and density of the tufts can be controlled, allowing for various textures and designs. It will be appreciated that the tufting provides versatility in texture and design, making it suitable for products such as the rugs and the carpets. The tufting is performed in 150 to 2500 GSM range. Figure 2b illustrates the method for producing rug from the recycled fibre.
[074] The term "air jet loom weaving" refers to a textile manufacturing process where fabric is created by interlacing recycled yarn using high-speed air jets. In this regard, the air jet looms use compressed air to insert the weft yarn through the warp yarn, creating the fabric. Herein, a flat fabric refers to a textile material with a smooth and even surface, commonly used for various applications such as clothing or linens. Herein, the tufted textile article refers to the textile products created through the tufting process, such as rugs, carpets, or other items with raised pile surfaces. Advantageously, the air jet loom weaving is known for its high-speed operation, leading to efficient and rapid fabric production. The air jet loom weaving results in the flat fabric with uniform texture, suitable for a variety of end products. The air jet loom weaving is suitable for weaving the fabrics used in garments, linens, or other flat applications. Beneficially, the tufting adds the texture and depth to the fabric, creating a visually appealing surface. In an embodiment, rapier or projectile looms with dobby or jacquard shedding mechanisms can be used as a suitable picking system.
[075] In another embodiment core spun yarn can be made. In this regard, the method includes wrapping the recycled yarn to create the core spun yarn, which can have various core compositions, contributing to the versatility of the fabric. The core spun yarn, with different core compositions, introduces variations in the fabric properties, such as strength, texture, and appearance. The core of 100% recycled fibre ensures the fabric sustainability. The blended core with the virgin cotton fibre combines the recycled fibre and the virgin cotton fibres for specific characteristics. The blended core with the virgin synthetic fibre introduces synthetic elements for enhanced properties. The complex blended core combines the recycled fibre, the virgin cotton fibre, and the virgin synthetic fibres for a customized blend. After the corespun yarn is formed, the method comprises weaving or tufting the corespun yarn to produce the fabric.
[076] In an embodiment, the fabric is subjected to wet processing. The term "wet processing" as used herein refers to a series of treatments applied to the fabric in a liquid medium, involving various stages to enhance its properties and appearance. Optionally, the fabric may be subjected to wet processing which includes following processes or sub-steps: desizing, scouring, bleaching, dyeing, printing, and finishing the fabric. Herein, desizing includes removal of sizing agents applied during weaving for smoother fabric. Scouring includes cleaning to eliminate impurities, waxes, and natural oils from the fabric. Bleaching includes whitening the fabric by removing color impurities. Dyeing includes applying color to the fabric for desired aesthetics. Printing includes adding patterns or designs onto the fabric. Finishing includes final treatments to improve texture, feel, and durability.
[077] Moreover, the wet processing is typically carried out in specialized machinery designed for each treatment stage. The various chemicals and dyes are applied at specific stages according to the treatment requirements. The wet processing enhances fabric qualities, improving softness, color vibrancy, and overall aesthetics. Herein, the textile products include products, such as towels, bathrobes, quilts, bath rugs, and bed sheets. The textile products are created by assembling and shaping the fabrics.
[078] Optionally, the fabrication process includes cutting the fabrics into patterns based on the product type. Optionally, the fabrication process includes sewing the fabric's pieces together to form the final textile product. Optionally, the fabrication process includes additional processes such as an embroidery or quilting based on the textile product. The made-up fabric obtained here is the finished textile product that is ready for use.
[079] Yet another aspect of the present disclosure relates to a fabric having the recycled fibres, as above. Accordingly, the embodiments pertaining to the recycled fibre are applicable here as well.
[080] In an embodiment, the fabric is made from 100% recycled fibre. In another embodiment, the fabric is made from blended fibre comprising at least 20% recycled fibre mixed with virgin cotton fibres and/or synthetic fibres. Suitable examples of fabric include such as, but not limited to, towel, bathrobe, fitted sheet, quilt, rugs, bedsheet, and the likes. The fabric of the present invention has similar properties as that obtained from fresh fibres or non-recycled fibres.
EXAMPLES
[081] The following examples are illustrative of the invention but not limitative of the scope thereof.
[082] Table 1 below is indicative of the hard waste generated in a textile industry processing cotton fibre.
Waste generated at Amount of waste
Fine count yarn hard 150 to 200 kg per day
Coarse count yarn hard waste 500 to 550 kg per day
OE yarn hard waste 20 to 30 kg per day
Flat fabric non-FRC waste 4.5 MT per day
Flat fabric FRC waste 900 kg per day
Flat fabric weaving hard waste 850 kg per day
Terry Fabric FRC waste 1.2 MT per day
Terry Fabric weaving hard waste 300 kg per day
Total yarn hard waste 800 to 900 kg per day
Total fabric hard waste 7.5 to 8 MT per day

[083] Notably, on one hand the virgin cotton requires a lot of water and land for the cultivation thereof and on the other hand there are tons of hard cotton waste generated per day.
[084] In the accompanying example of the present invention, textile waste material from an industrial setup was processed to obtain recycled fibres. For this, the waste material was a cotton rich weaving waste comprising a mixture of yarn hard waste, open-end yarn hard waste, BS non-FRC waste, BS FRC waste, BS weaving hard waste, towel FRC waste, and towel weaving hard waste. Subsequently, the waste material was cut into lengths ranging 20 mm to 80 mm to obtain the cut textile waste material. The cut textile waste material was passed through one or more opening rollers and air blowing unit to obtain the opened fibres. Finally, the opened fibres were subjected to carding to obtain the recycled fibres. Table 2 below provides a comparison between the recycled fibres of the present invention vs virgin cotton (S-4 & S-6).
Virgin Cotton: S-4 Virgin Cotton: S-6 Recycled Fibres
MIC 3.9 to 4.5 3.7 to 4.1 3.7 to 4.5
UHML 27.5 to 28.8 28.8 to 30 15.0 to 28.2
UI% 81.74 82.92 77.7
SFI 9.39 7.81 14.9
Strength 28.32 30.73 27.0-30.7
Elongation 6.83 6.38 5.0 to 7.0
+b 9.4 8.4 10.4
Hard End % 0 0 Less than 2%

[085] As will be noted above, the recycled fibre of the present invention achieve similar performance as that of the virgin cotton.
[086] The foregoing description of the invention has been set merely to illustrate the invention and is not intended to be limiting. While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.
,CLAIMS:WE CLAIM:

1. A method for recycling a textile waste material, comprising the steps of:
a. collecting the textile waste material;
b. cutting the collected textile waste material into a predefined length to obtain a cut textile waste material;
c. passing the cut textile waste material through one or more opening rollers and/or an air blowing unit to obtain opened fibres; and
d. optionally carding the opened fibres to produce recycled fibres.

2. The method as claimed in claim 1, wherein the textile waste material is a discarded or unused textile or fabric-based product, the textile waste material made from fibres selected from the group consisting of cotton, flax, hemp, wool, silk, asbestos, polyester, nylon, rayon, man-made fiber, cellulosic fiber, derivative of cellulosic fiber, acrylic, synthetic fiber, recycled synthetic fibre and/or natural fibre and/or man-made fibre, and combinations thereof.

3. The method as claimed in claim 1, wherein the textile waste material is selected from the group consisting of yarn hard waste, open-end yarn hard waste, Bed Sheets non-Fent Rags Chindi waste, Bed Sheets Fent Rags Chindi waste, Bed Sheets weaving hard waste, towel Fent Rags Chindi waste, and towel weaving hard waste

4. The method as claimed in claim 1, wherein the pre-defined length ranges between 20 mm to 80 mm.

5. The method as claimed in claim 1, wherein the opened fibres contain open and separate fibres of the cut textile waste material.

6. The method as claimed in claim 1, wherein the step of passing the cut textile waste material through the one or more opening rollers and/or the air blowing unit reduces a number of hard ends to below 25%.

7. The method as claimed in any of claims 1 to 6, wherein the step of carding further reduces the number of hard ends to less than 2%.

8. A yarn comprising the recycled fibre produced from the method as claimed in any of claims 1 to 7, wherein the recycled fiber is characterized by: a mean micronaire (MIC) value ranges between 3.7 to 4.5, an upper half mean length (UHML) value ranges between 15.0 to 28.2, a uniformity index (UI%) ranges between 77 to 81, a specific fibre strength index (SFI) value ranges between 10 to 20, tensile strength ranges between 15.0- 32, an elongation value ranges between 5 to 7, a yellowness index (+b) ranges between 9 to 10.4, and the number of hard ends is less than 2%.

9. A method for producing a fabric, comprising the steps of:
(A) obtaining the yarn as claimed in claim 8, the yarn comprising at least 20 wt.% of the recycled fibre; and
(B) weaving or tufting the yarn to produce the fabric.

10. The method as claimed in claim 9, wherein the yarn is produced by:
(a) feeding the recycled fibres to a blow room machine to obtain opened and loosened fibres;
(b) carding the opened and loosened fibres in a carding machine to obtain a sliver containing the recycled fibres;
(c) drawing the sliver in one or more drawing units;
(d) transferring the sliver to a speed frame unit to obtain a roving; and
(e) spinning the roving in a ring spinning unit or an open-end spinning unit to produce the yarn.

11. The method as claimed in claim 9, wherein the yarn is produced by:
(a) feeding the recycled fibres to a blow room machine to obtain opened and loosened fibres;
(b) carding the opened and loosened fibres in a carding machine to obtain a sliver containing the recycled fibres;
(c) drawing the sliver in one or more drawing units; and
(d) feeding the sliver to a rotor or an air jet machine to obtain the yarn.

12. The method as claimed in claim 10 or 11, wherein the yarn is a single yarn or a double yarn or a multiplied yarn.

13. The method as claimed in claim 10 or 11, wherein the sliver obtained from the one or more drawing units is optionally subjected to combing in a combing unit to remove shorter fibres and impurities from the sliver.

14. The method as claimed in claim 10 or 11, wherein the recycled fibre is blended with one or more natural fibres, man-made fibres, cellulosic fibres, and/or synthetic fibres.

15. The method as claimed in claim 9, wherein the fabric is subjected to wet processing which includes one or more of the following steps: conditioning, washing, desizing, scouring, bleaching, dyeing, printing, and finishing.

16. The method as claimed in claim 9, wherein the fabric is selected from the group consisting of a flat fabric, a terry fabric, tufted fabric, loop/cut loop and derivatives thereof.

Dated this 5th day of February 2024.

Welspun Living Limited
By their Agent & Attorney

(Nikhil Ranjan)
of Khaitan & Co
Reg No IN/PA-1471