Available online at http://www.urpjournals.

com

International Journal of Fiber and Textile Research

Universal Research Publications. All rights reserved

ISSN 2277-7156
Review Article
Recycled fibers: An overview
Dinesh Bhatia1, Ankush Sharma2 and Urvashi Malhotra3
Department of Textile Technology
1,2
Dr. B.R. Ambedkar National Institute of Technology, Jalandhar (India) 144011
3
J.N.G.E.C Sundernagar, Himachal Pradesh (India) 175018
Cell: +91 8054603399, E mail: dineshbhatia55@rediffmail.com
Received 30 October 2014; accepted 13 November 2014
Abstract
Today, in the world of modern technologies, the demand for production is increasing so rapidly in all aspects of the
required living commodities. In order to meet all the required demands, over production and utilization of all resources
seem not enough. Therefore, the increasing demand for textile making huge clothing production is not only based on
demand for more population but it’s also changing new fashion habits as well. Improving raw material exploitation has
become the most important challenge facing scientific and industrial community. Textile production wastes are undesirable
but inevitable by- products in many manufacturing process (spinning, weaving, knitting, or garment manufacturing) and
are frequently undervalued. However, if one can convert such wastes into useful product economically, there will be great
contribution to the market. In this paper attempt has been made to give idea about different types of waste produced in
textile industries (spinning, weaving, knitting, or garment manufacturing) and also types of waste which can be used again
in recycling process to make some value added product. Also give different types of methods by which this waste can be
used to make new high quality products from existing material.
© 2014 Universal Research Publications. All rights reserved
Keywords: Fibers, Recycled, Textile and Waste.

1. Introduction which requires opening on special machines, examples are

A situation of production waste has developed since the twisted roving, yarns, and textile fabrics (woven rags and
industrial revolution. As demand increased, the knitted rags) [1]. In the past, waste produced during the
manufacturing industry evolved and manual labour systems manufacturing processes (spinning, weaving and knitting)
were replaced by mechanized manufacturing. This allowed was normally collected and sold to the waste spinner for
textile to be produced cheaper, quicker and in vast relatively low prices. Certain blending of wastes with good
qualities. This has resulted in an overabundance of mass materials was necessary in order to upgrade the quality of
produced cheap and often poor quality products and large waste yarns produced and prevent excessive end breakage
volume of textile fibers waste that has limited end use rate during spinning.
applications. Textile production wastes cover all those raw With ever increasing price hike of both cotton and
materials which are either accruing or being used in the manmade fibres, most of the export avenues downing their
textile industry such as production remnants, wastes from shutters, heavy investments on sophisticated machines and
fibre and filament manufacture, wastes from spinning, modernisation with doubtful returns and above all labour
weaving, knitting and making-up as well as reprocessed demanding ever increasing wages with disproportionate
materials. and decreasing productivity, many of the textile mills are in
Textile production wastes fall into three categories : (a) doldrums. Inflation and increasing unemployment have
trashy waste - waste which requires cleaning before further reduced demands for garments and clothing. Hence
reprocessing, examples are blow room wastes, carding in order to survive the heavy competition, it is absolutely
waste, card flat strips and filter waste; (b) clean waste - essential that waste incurred during manufacturing
waste which requires no further cleaning, examples are processes should be brought within critical limits or
comber waste, card, draw frame and combed sliver waste, recycled that waste to produce a value added products in
filter waste from draw frames, speed frames, ring spinning place of selling it at low price.
frames and rotor spinning machines; (c) hard waste - waste To overcome this problems number of company produced

International Journal of Fiber and Textile Research 2014; 4(4): 77-82

77
different methods of recycling process. The company 2. Types of waste
Patagonia in the US now recycles many garments made 2.1 Preconsumer Waste
from Polartec polyester fabric [2]. In Turkey, recycled Pre-consumer waste is a material that was discarded
polypropylene is reinforced with silk and cotton waste, before it was ready for consumer use. Pre-consumer
resulting in a composite with improved mechanical and recycled materials can be broken down and remade into
physical properties [3]. Upholstery and automotive needle similar or different materials, or can be sold "as is" to third
punch fabric manufacturers experience an increased party buyers who then use those materials for consumer
demand for polyester recycled fibres, for which products. Preconsumer textile waste usually refers to waste
conventional recycling processes of making reclaimed by-products from fiber, yarn, textile, and apparel
fibres can well be used [4]. Denim cutting-room scraps manufacturing. It can be mill ends, scraps, clippings, or
pose an environmental and economic problem. Burlington goods damaged during production, and most is reclaimed
Industries and North Carolina State University have at last and reused as raw materials for the automotive, furniture,
come up with a solution and have developed a technique to mattress, coarse yarn, home furnishing, paper, and other
make jeans, in part, from reclaimed denim. The denim is industries [9].
made from 50% reclaimed denim yarn and 50% virgin 2.2 Postconsumer Waste
cotton yarn [5]. Another innovative use of denim scraps is Postconsumer textile waste usually refers to any product
the manufacturing of unbleached 100% cotton rag paper, that the individual no longer needs and decides to discard
called Blue Jean Bond, which is undertaken by Esleeck in due to wear or damage and normally includes used or worn
the US. clothing, bed linens, towels, and other consumer textiles.
Products made from recycled fabric waste include Postconsumer waste which can be recovered are clothing,
nonwovens used for insulation, padding, upholstery, oil drapes/curtains, towels, sheets and blankets, clean rags and
filters, hospital drapes and gowns, as well as a variety of sewing remnants, table cloths belts hand bags paired shoes
absorbent products like disposable wipes, geotextiles, and socks [10].
carpets, fibrefill and spun-bonded fabrics from 3. Classification of waste on the basis of production
polyethylene. Many other products such as trims from industry:
unravelled knits are also manufactured [4, 6]. Flocked Different types of waste produced in different types of
fibres from finely cut fabric waste those are applied to production industries are given in Table 3.1.
adhesive-coated surfaces and then used for various Table 3.1 Types of waste produced in different production
purposes for instance packaging materials for jewellery, is industries.
another practice [7]. Production Type Types of waste
A process for using recycled waste material for producing a Opening Waste, Carding Waste, Sliver Waste,
textile product is provided. This process can include Spinning waste, Roving Waste, Combed Noil, Bonda soft waste,
collecting different categories of waste material from a yarn waste Pneumafil Waste, Bonda hard waste from ring
spinning, winding and doubling.
variety of textile formation processes. The process can also Knitting waste fiber and yarn, Woven waste fiber
include selecting specific categories of waste material to be Clothing waste
and yarn, Woven and knit cutting waste.
blended together depending on the final textile product to Nonwovens Thermally and chemically bonded, lightweight
be produced. Recycling of textile waste gives fiber a production waste webs, needled webs, coated, uncoated.
Needle felt, tufted carpet, cut waste, coated,
second life in a rejuvenated life cycle and thus increases the Carpet mill waste
uncoated
total value of that recycled fibre. Still most of recycled Used textiles Old clothing
fibres end up in low value products, so the development of
new higher value products from recycled fibres will
4. Benefits of Recycling Waste
encourage utilization of the waste fibres and contribute to
Using recycling waste can benefit both business and the
the future sustainability of industry.
 Reducing cost of purchasing materials.
environment by:
Today, recycling has become a necessity not only because
 Increasing profitability.
of the shortage of any item but also to control pollution.
 Minimizing costs of disposal and treatments.
There are three ways to reduce pollution. One is to use
 Minimizing environmental impacts by reducing use of
newer technologies that pollute less. The other is to
effectively treat the effluent so that the final effluent
conforms to the expected norms. The third and the most new raw materials and producing products from earlier

 Textile recycling requires less energy than any other

practical way are to recycle the waste several times before one.
it is discharged [8].

 Textile recycling does not create any new hazardous

In the study, the attempt has made to describe the wastage type of recycling.
amount of various textile process along with their
classification, in addition to that it also describe textile waste or harmful by-products.
recycling techniques. The target is to form different 5. Method of converting old clothing into fibers
categories of waste produced from different sources like, Before going into different applications of recycled fibers
spinning, weaving, knitting and garment manufacturing. It firstly we know about the procedure of converting old
includes the waste that is recyclable along with its clothes into fibres. Old clothes are converted into fibers by
recycling process; on the other hand different application following operations. (1) Freed from dust. (2) Carefully
areas are also introduced. sorted. (3) Oiled so they will be soft and pliable. (4) Then

International Journal of Fiber and Textile Research 2014; 4(4): 77-82

78
converted into strip- form of particular dimensions stuffing of pillows and quilts. Some use this waste for
according to specification of rag puller. (5) Then, the strips making fancy composites for floor covering. By using
were distributed evenly on the feed lattice. As the strips 100% wool yarn for 100% wool weft or polyester-wool
were delivered by means of feed roller, the torn-out blended yarn, the wool rich catch selvedge can be teased to
garment strips were torn-off by the high speed spiked recover fibres to feed to the woollen cards to produce
beater. The fibres produced were collected at the container blankets which have a market in cooler regions. This is a
while the unfilled-opened strips were collected at the cost effective solution and provides for the wool rich raw
separator for re-processing [11]. materials needed for producing blankets [8].
6. Fiber Recycling Technologies 6.3 Composite Biomaterials from Recycled Fibers
A vast number of products are made from reprocessed fiber Protein fiber wastes such as by-products from the wool
because much of this fiber is re-spun into new yarns or textile industry, poor quality raw wools not fit for spinning,
manufactured into woven, knitted, or non-woven represent an important renewable source of biopolymers.
fabrications, or upholstery material, or composite Hairs and feathers are largely made of keratin, that could be
biomaterial, or other methods including garment linings, recovered and transformed into new materials with
household items, furniture upholstery, insulation materials, innovative properties suitable for textile or non-textile uses
automobile sound absorption materials, automobile (fibers, compostable packaging, disposables, agricultural
carpeting, and toys [12]. films, membranes and coatings). Wool fibers when
6.1 Yarns from Recycled Fibres disrupted in their histological components attaching the
The waste produced in a textile mill is an important factor intercellular cement by ultrasonic-enzyme treatments, the
in determining the operating cost and therefore in resulting cells were embedded in a polymeric film-forming
influencing mill profits. The recovered fibers from waste matrix of cellulose acetate, of obtaining new composite
can be used to produce blended yarns (waste/virgin fibers) material, suitable for film production and filament
in different portions. These fibers can be reused for the spinning. Cellulose acetate is largely used in the production
open end spinning and friction spinning but nowadays of yarns for textiles, filters, plastics; electrical insulations,
attempts on ring spinning are also in progress. The photographic films, transparent and pigmented sheets,
requirements of quality imposed on the finished products medical and sanitary application since it exhibit a
allow only the addition of tiny quantities of recovered remarkable resistance to moulds and bacteria. Nevertheless,
fibers. Therefore the proportion of secondary raw material cellulose acetate is highly flammable and very difficult to
blended with primary material must be carefully studied. In dye. Plastics and textile fibres with novel properties, such
a study focused to the rotor spinning process concluded that as improved fire resistance, moisture regain, dyeing
up to 20% of recovered fibers can be blended with primary performances and colour effects, handle and look might be
raw material without noticeable changes in quality. It is produced from new composite materials combining
found from the studies that the introduction of 15 and 25% properties of man-made and protein polymers which are
waste fiber into the cotton will not affect the tenacity, the naturally hydrophilic, non-burning and dyed well by most
irregularity and the rotor yarn elongation. Results also of the commercial dye-stuffs. Improvement of the thermal
indicated that the recovered fibers have a good clean ability properties has been obtained with respect to the pure
which allows its blend with virgin fibres. This yarn can be cellulose acetate film. Cortical cells from wool also give to
woven or knitted for some special purpose but till a date it cellulose acetate a more hydrophilic character and,
is not able to fulfil the work of virgin fibres. Researchers potentially, other performances typical of wool, such as
claimed that yarn can be used for specific use if waste is novel dyeing properties and colour effects, which are very
selected in specific amounts from the various waste important characteristics for textile applications [13].
categories and mixed together properly. For example, a 6.4 Nonwovens made from Recycled Fibres
formula that includes the percentage by weight of the type Depending on product functions, reclaimed fibres can be
of waste from the various waste categories can be used that looked upon as conventional in technical textiles,
is based on characteristics of the yarn to be produced. particularly in nonwoven (mobility textiles which mainly
Researcher make yarn of 100 % cotton waste (30% ring serve to cover up surfaces or to insulate materials, agro-
spinning waste; 30% card waste; 20% weaving yarn waste; textiles, and geo-textiles which are used to protect soil
and 20% combed waste yarn) that has a count of 24/1 Ne against erosion). In all these cases, reclaimed fibres are
which can be used for a warp yarn in producing a woven used because of low prices, or because they merely cover
bed sheeting. Attempt on making Dref yarns from recycled something up. However, reclaimed fibres are also applied
fibres also shows good results but as raw materials used is in nonwoven to utilise highly valuable functional
totally waste materials so fabrics produced of course components. This concerns fibres, which would not be
belongs to cheap fabrics which are suggested to be used in available at a competitive price if made from primary

 The high- grade woollen hair found in laminated

the field of cleaning cloths, wrapping cloths and covering material, such as:
cloths [11].

 Aramide fibers used to protect against cutting or

6.2 Upholstery material From Recycled Fibers nonwoven used to make motor vehicle seats.
At least 3-4% of the weft yarn including catch ends is

 Micro- fiber materials used for insulation or cleaning.

unavoidable waste in every type of weaving machine. The impact penetration.
catch selvedge yarn strip is sold at throw away price. The
fibres are separated by the garnetter who uses them for Geo - textiles may be looked upon as an ideal field for the

International Journal of Fiber and Textile Research 2014; 4(4): 77-82

79
Table 6.1 Requirements to be met by technical textiles.
Most urgent requirement to be met by recycled fibres
Application
Polymer Fineness Strength Length Colour
Reinforcing fibre X X
Wrap yarn for technical textiles X X X X
Nonwoven to protect against erosion X X
Geotextile nonwoven X X X X

application of reclaimed fibres. To make them, it is 6.5.3 Stuffed toys

important to use well-selected textile waste and to exactly Stuffed toys are made of different type of textile, normally
tune the process parameters when breaking it up. In this textile is recycled. In this kind of toys are made from plain
way quality requirement below in Table 6.1 can be met clothes and pile textile, in addition there are other type
[14]. of textile like, cotton, synthetic fiber batting and terrycloth.
6.5 Other Method of Using recycled Fibers. These types of toys are used for comfort as well as playing
6.5.1 Insulation Materials for kids. Stuffed toys made of textile waste are shown in
Insulation materials are an important part in construction, Figure 6.3.
material are used for the ventilation purposes and
conduction, radiation and thermal insulation. Therefore
Insulation materials are made from textile waste, insulation
material is the key to keep balance of energy consumption.
Insulation material made up of textile waste is shown in
Figure 6.1.

Figure 6.3 Stuffed toys made of textile waste.

6.5.4 Shoe insoles
Shoes insoles are important to make for shoes, they are
used underneath in the shoes in order to make shoes more
Figure 6.1 The insulation material made from textile waste.
comfortable to wear, and they can be easily removed from
6.5.2 Carpet underlay the shoes. Some examples of shoe insoles are shown in
Generally carpet underlay is the thin layer of cushioning Figure 6.4.
which is used in different form of carpets which are used
for different purposes. Therefore, the categories and types
of underlay vary like, sponge rubber, foam and crumb
rubber. Thus, it is also used in the carpet in order to
moisture noise and heat. Some examples of underlay carpet
are shown in Figure 6.2.

Figure 6.2 Example of underlay carpet. Figure 6.4 Example of shoe insoles.
International Journal of Fiber and Textile Research 2014; 4(4): 77-82
80
Table 7.1 Industries which uses recycled fibres along with their application area
Industry Application Area

Automobile industry: insulating webs for sound and heat insulation, hard-
pressed parts for floors, side and seat linings, trunk compartment, luggage dump
Nonwovens industry
etc., bottom felts for carpeting, stitch-knit nonwovens (Moliwatt, Molivlies).
Mattress covers, mattress webs, bottom webs for seating in furniture, upholstery
material, wadding material.
Furniture industry Wiping cloths
Needled webs.

Carpet industry Bottom felts for carpeting

Sound and heat insulating webs, filter products, nonwoven coating substrates,
Building industry and footfall sound insulation. Textile shreds as filling material for insulating
webs, as aggregate for textile concrete in road construction.

Spinning waste, blended yarns or 100% waste yarns for spinning to the DREF
or rotor spinning process (wiping cloths, blankets, and home furnishings),
Textile industry
comforters made of acrylic knit goods waste.

Agriculture industry Covering webs, seed carrier webs.

Paper industry Wearing felts for paper production, Crude felts for bitumen roofing felts.

7. Uses and Ranges of Application for Recycled Textile recycled fibres are shown in Table 7.1.

 Promoting waste avoidance on purely environmental

Fibres 8. Limitation of Recycling
Reclaimed fibres can be manufactured from a variety of
textile waste. Both quality and process ability of such fibres reasons may not be sufficient. As costs for collection
depend on the kind of waste. Well-known are the pure and disposal services are not linked directly with the
sorted fibres of high-quality which are achieved from quantity and sorting of wastes generated through

 There is no financial incentive for waste producers to

spinning-fibre waste. In contrast, reclaimed fibres made charging,
from end-of-life textiles are of much poorer quality. They

 Low values, high transportation cost or lack of market

will rarely be found of homogenous fiber type. reduce waste.
There are many ways open to using reclaimed fibres in both
textile and non-textile products. The suitability of processes
 The predominance of small and medium recovery and
demand for recovered materials particularly.
depends on waste characteristics and on how much they
cost. Yarns are a frequent example of how reclaimed fibres recycling enterprises discourages investments in waste
can be used. Yarns made from reclaimed fibres may serve recovery technologies.
to produce fabrics for garment and household textiles as 9. Conclusion
well as for simple technical applications. However, as yarns A large amount of textile waste is disposed of in landfills
made from reclaimed fibres, in most cases, are grey or dark each year. That not only poses economic and
by nature, they are not frequently used in garment or environmental problems to the society but also represents a
household textiles. With technical yarns, colour ranks in severe waste of resources. Although the environmental
second place. Even special-purpose fibre materials are awareness of the general public has increased significantly
made into reclaimed fibres today. in recent years, still their willingness to actively participate
In the following, a few examples of possible uses in the in waste reduction by recycling needs to be enhanced. Fiber
snonwovens, carpet, building, textiles, agricultural and recycling technologies, usage and range of application of
paper industries are given, but new ranges of application recycled fibres described in this paper will become a handy
are opened up every day (see Figure 7.1). The various uses tool to assimilate the waste as value added product, which
mainly depend on how the textile and nonwovens waste is waste was earlier considered as garbage and sold unduly.
formed during the individual process stages. This will then So people those are impetuous for waste disposal would
determine the possible recycling process. Consequently, think rationally about the rejuvenation of waste fibers for
various technologies are required for reprocessing. Some raise the profit for their firm and also it reflects noble cause
industries along with their application area which uses for society by reducing the contamination in environment.
International Journal of Fiber and Textile Research 2014; 4(4): 77-82
81
 Figure 7.1 Reuse and recyclability of textile waste.
Refrences 154–160.
1. Yarn and Fabrics from Textile Wastes, 8. A.D. Sule, M K Bardhan, Recycling of textile waste
www.cottonyarn- - market.net. for environmental protection: An overview of some
2. S. McDavid (ed.), All Polartec fabrics now recyclable, practical cases in textile industry, Indian journal of
AATCC review. 7 (2007) 18. fiber and textile research. 26 (2001) 223-232.
3. M. Taþdemir, D. Koçak, Ý. Usta, M. Akalin, & N. 9. A. Roznev, E. Puzakova, F. Akpedeye, I. Sillstén, O.
Merdan, Properties of polypropylene composite Dele, O. Ilori, Recycling in textiles, HAMK University
produced with silk and cotton fiber waste as of Applied Sciences Supply Chain Management.
reinforcement, International Journal of Polymeric 10. B. Platt, Weaving Textile Reuse into Waste
Materials. 56 (2007) 1155–1165. Reduction, Institute for Local Self-Reliance
4. B. Gulich, Designing textile products that are easy to Washington. (1997).
recycle. In: Wang Y. (ed.) Recycling in Textiles, 11. K.P.S. Cheng, K.F. Wong, Processing and properties
Woodhead Publishing Ltd, Cambridge, UK. (2006a) of yarn and fabrics from textile production wastes.
29–31. Georgia Institute of Technology. (1997).
5. M. Folk, Making use of scraps: Burlington finds way 12. Y. Wang, Recycling in textiles, Woodhead Publishing
to turn yarn into jeans. Greensboro News and Record, in textiles (2006).
October, 4 (1994). 13. A. Aluigi, C. Vineis , A. Ceria , C. Tonin, Composite
6. M. Larney, A.M. van Aardt, M. Grasso, Recycling of biomaterials from fibre wastes: Characterization of
textiles: green panacea or red herring?, Journal of wool–cellulose acetate blends, Composites Part A:
Dietetics and Home Economics. 24 (1996) 83–89. Applied Sciences and Manufacturing. 39 (2008) 126–
7. K.D. Langley, Y.K. Kim, Manufacturing nonwovens 132.
and other products using recycled fibers containing 14. B. Gulich, Development of products made of
Spandex. In: Wang Y. (ed.) Recycling in Textiles, reclaimed fibres: Recycling in textiles, Woodhead
Woodhead Publishing Ltd, Cambridge, UK. (2006) Publishing in textiles. (2006).

Source of support: Nil; Conflict of interest: None declared

International Journal of Fiber and Textile Research 2014; 4(4): 77-82
82