Abstract
Conventional denim production is plagued by the issue of wastewater pollution from warp dyeing. In this investigation, recycled cotton (R-CO), virgin cotton (V-CO), and dope-dyed recycled polyester (R-PET) fibers were spun into blue/white spaced warp yarns through a dual-feed-opening rotor spinning technique. These yarns were woven with V-CO weft yarns to produce fabrics featuring the classic denim color scheme of blue and white stripes, without the need for warp dyeing and complex finishing processes. The resulting fabrics fulfilled industry standards for tensile strength (>600 N), tearing resistance (>50 N), abrasion resistance (>25000 cycles), pH (≈6.5), and formaldehyde content (<10 mg/kg). The fabrics' air/moisture permeability and wearability (including crease-resistance, flexibility, drapability, and washing size stability) were outstanding. The fabrics' light and crocking colorfastness ratings all exceed grade 4, indicating excellent performance. A rise in R-CO content resulted in the degradation of several properties. The production of the denim covered by this study was more cost-effective and environment-friendly than that of conventional denim. This research provides a paradigm for the conversion of waste textiles into value-added and eco-friendly textile products.
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