DESC:FIELD OF THE INVENTION
The present invention relates to a method of manufacturing denim fabric from cellulosic based recycled fibre.
BACKGROUND OF THE INVENTION
Apparel industry has different types of sustainable and eco-friendly products made from cellulosic material, synthetic material or combination of both. The product made from only synthetic material and its blend with cellulosic fibre may cause irritation to the user and has less moisture absorption property. The product made from cellulosic material gives more comfort to the user. The cellulosic material is obtained from the nature and they are used in fabric making. However, in order to reduce use of natural fibres, recycled fibres may also be used.
In current state of art, mechanically recycled cellulosic fibres are used in the industry. However, the processes of manufacturing fabric from cellulosic based mechanically recycled fibres, are complex and the fabric may have a lot of defects. The complexity and defects may occur because of mechanically recycled fibres are of shorter length, thus undergo frequent breakage that leads to loss of efficiency during manufacturing process. To overcome this problem, synthetic recycled fibres are added to the cellulosic recycled fibres for providing strength, however it may cause discomfort to the user. It also creates defect at fabric/garment stage such as pilling, uneven dyeing etc.
Accordingly, there is need of a method of making yarns/fabric from only cellulosic recycled fibres that overcomes drawbacks of the methods of making yarn of undergoing frequent breaking.

SUMMARY OF THE INVENTION
The present invention relates to a method of manufacturing a fabric from a cellulosic based recycled fibre. In first step, a chemically recycled cellulosic fibres of about 20 – 100% and mechanically recycled cellulosic fibres of about 0 – 80% are mixed for preparing a yarn. The contribution of chemically recycled fibres and mechanically recycled fibres is selected to get the yarn tenacity of at least 13 cN/Tex. The chemically recycled fibres and mechanically recycled cellulosic fibres include fibres obtained from post- consumer waste (PCW) and/or post/pre- industrial waste (PIW). The yarn count ranges between 4s – 40s Ne and more particularly, the yarn count ranges between 6s - 20s Ne. In the next step, the fabric is woven in a predefined pattern. In the last step, the woven fabric undergoes finishing. The post/pre industrial waste fibres are obtained from undyed or dyed cotton yarn waste or fabric waste from woven/knitting industries. The post-consumer waste fibres are obtained from used garments. The recycled yarn is made by using open end spinning or ring spinning technique. The weft and/or warp yarn of recycled fibres are dyed with textile class of dyes such as oxidative dyes, direct dyes, vat dyes, basic dyes, reactive dyes, pigment dyes etc. The weaving of the fabric includes twill weave pattern. The finishing process includes sequential steps of singing, desizing, heat set, printing, coating, emerizing, brushing and over dyeing. The finishing process steps are selected based on fabric end use requirement. The fabric contains 0 – 80% mechanically recycled fibre and 20 – 100% chemically recycled fibres. The mechanical and chemical recycled fibres include cotton and regenerated cellulosic fibres. The regenerated cellulosic fibres include viscose, modal and lyocell. The contribution of chemically recycled fibres and mechanically recycled fibres is selected to get the yarn tenacity of at least 13 cN/Tex. In one aspect, the present invention also provides a cellulosic yarn comprising cellulosic based recycled fibres only, the cellulosic based recycle fibres includes a mixture of chemically recycled cellulosic fibres of about 20 – 100% and mechanically recycled cellulosic fibres of about 0 – 80% to form a yarn having tenacity at least 13 cN/Tex and count ranges between 4s - 40s Ne.

BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic diagram of a method of manufacturing fabric.

DETAIL DESCRIPTION OF THE INVENTION
Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to particular structure of the invention selected for illustration in the drawings, and are not intended to define or limit the scope of the invention.
The present invention provides a fabric having cellulosic based recycled fibres selected from chemically recycled fibres and a mechanically recycled fibre. The recycled fibres can be selected from post/ pre industrial waste (hereinafter referred as “PIW”), post-consumer waste (hereinafter referred as “PCW”) or a combination thereof.
Referring to FIG. 1, a schematic diagram of a method of manufacturing a fabric using only recycled fibres in accordance with an embodiment is shown. In accordance with the present invention, two types of recycled fibres have been used, a chemically recycled cellulosic fibres and a mechanically recycled cellulosic fibres. The recycled cellulosic yarn is made by using open end spinning technique or, ring spinning technique. The recycled cellulosic yarn has mechanically recycled fibres and chemically recycled fibres PCW and/or PIW. The PIW fibres are selected from undyed cotton yarn waste and fabric waste from woven/knitting industries. The PCW fibres are selected form used garment. The recycled fibre fabric may contain stretch filament
The yarn made up of only mechanically recycled cellulosic fabric is not suitable for all application due to low strength yarn/fabric, frequent yarn breakage during process etc so the supporting fibres are required. The method of present invention facilitates use of 20% - 100% chemically recycled fibres as supporting fibres to strengthen the mechanically recycled fibres to make a fabric made up of only recycled cellulosic fibres.
In accordance with an embodiment, the obtained recycled yarn undergoes either dyeing or fabric manufacturing process. The recycled yarn is dyed with any textile class of dyes such as oxidative dyes, direct dyes, vat dyes, basic dyes, reactive dyes, pigment dyes etc. In an embodiment, the recycled yarn is dyed with indigo dye followed by fabric manufacturing process. The fabric is woven or knitted in a predefined pattern. In an embodiment, the fabric is woven with twill weave to get denim look. The fabric weave includes plain, twill, satin/sateen, dobby weave pattern. The warp and weft yarn are interlaced together to make fabric, in an embodiment, the weft and warp yarns are made only from the recycled fibres. The weft yarn and/ or warp yarn may include stretch fibres or filament.
The fabric is dyed with any textile class of dyes such as oxidative dyes, direct dyes, vat dyes, basic dyes, reactive dyes, pigment and the like. The fabric manufactured by the method of manufacturing as described above, has cellulosic based recycled fibres only. This fabric undergoes finishing process to get fabric with desired aesthetic look. The finishing process includes singing, desizing, heat set, printing, coating, emerizing, brushing, over dyeing etc. The finished fabric is used for making garments.
In accordance with an embodiment, the fabric contains 0 – 80% mechanically recycled cellulosic fibre and 20 – 100% chemically recycled cellulosic fibre. The warp and weft yarn contains only recycled cellulosic fibre, and it may have stretch fibres or filament. The yarn count ranges between 4s – 40s Ne. More particularly, it ranges between 6s - 20s Ne. The stretch filament count ranges from 20 – 140 Denier. The fabric weight ranges from 6 – 16 Oz/sq. yard. The contribution of chemically recycled fibres and mechanically recycled fibres is selected in such a way that the yarn tenacity of at least 13 cN/Tex.
Example:
Product A
Fabric composition:
70% mechanically recycled cellulosic based fibres and 30% chemically recycled cellulosic based fibres
Warp: 7 Ne
Weft: 7 Ne
EPI*PPI: 63*43
Weight: 13.5 Oz
Yarn Tenacity: 14 cN/ Tex
Result:
Tensile strength (KG) Warp: 80 Weft: 50
Tear Strength (Grams) Warp: 4300 Weft: 3050
The invention has been described in detail with reference to preferred and alternative embodiments thereof. However, it will be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.

,CLAIMS:
1. A method of manufacturing a fabric from cellulosic based recycled fibre only, the method comprises the steps of:
preparing yarns by mixing chemically recycled cellulosic fibres of about 20 – 100% and mechanically recycled cellulosic fibres of about 0 – 80%, the yarns having a yarn count ranges between 4s - 40s Ne and yarn tenacity of at least 13 cN/Tex;
weaving a fabric from the yarns in a predefined pattern; and
finishing the woven fabric.

2. The method as claimed in claim 1, wherein the chemically recycled cellulosic fibres include fibres obtained from post consumer waste (PCW) and/or pre/post industrial waste (PIW).

3. The method as claimed in claim 1, wherein the mechanically recycled cellulosic fibres include fibre obtained from post -consumer waste (PCW) and/or pre/post industrial waste (PIW).

4. The method as claimed in claim 1, wherein the pre/post industrial waste fibres are selected from undyed/dyed cotton yarn waste or fabric waste from woven/knitting industries.

5. The method as claimed in claim 1, wherein the post-consumer waste fibres are selected from used garments.

6. The method as claimed in claim 1, wherein the yarn is made by using open end spinning or ring spinning technique.

7. The method as claimed in claim 1, wherein the yarn of recycled fibres are dyed with textile class of dyes such as oxidative dyes, direct dyes, vat dyes, basic dyes, reactive dyes, pigment.
8. The method as claimed in claim 1, wherein the weaving of the fabric includes plain, twill, satin/sateen, dobby weave pattern.

9. The method as claimed in claim 1, wherein the finishing process includes sequential steps of singing, desizing, heat set, printing, coating, emerizing, brushing and over dyeing.

10. A fabric obtained from cellulosic based recycled fibres only, said fabric a having a chemically recycled cellulosic fibres of about 20 – 100% and mechanically recycled cellulosic fibres of about 0 – 80%.

11. The fabric as claimed in claim 10, wherein the yarn count ranges between 6s - 20s Ne.

12. The fabric as claimed in claim 10, wherein the recycled fibre fabric may contain stretch filament.

13. A garment manufactured from the fabric as claimed in claims 10-12.

14. A cellulosic yarn comprising cellulosic based recycled fibres only, the cellulosic based recycle fibres includes a mixture of chemically recycled cellulosic fibres of about 20 – 100% and mechanically recycled cellulosic fibres of about 0 – 80% to form a yarn having tenacity at least 13 cN/Tex and count ranges between 4s - 40s Ne.