Integrating Soft Waste Into Composite Yarn Manufacturing: A Multi-Criteria Decision-Making Approach

The spinning industries negatively impact the environment by generating substantial process waste. Unlike previous studies that primarily focus on recycling textile waste, this study explores a sustainable practice by incorporating process waste (soft waste) into manufacturing techniques to produce composite yarn with different components, including virgin cotton, elastane (Lycra(R)), and polybutylene terephthalate (PBT), using the modified spinning technique (ring). The article investigates the characteristics of yarns made from six various percentages of process waste (0% to 50%) and 100% cotton (virgin). The research examines the influence of process waste on composite yarn characteristics, and results demonstrate that increasing soft waste content from 0% to 50% leads to a significant increase in unevenness (from 12.05 to 14.03), IPI (from 47 to 163/km), and hairiness (from 7.02 to 7.89), while tensile strength decreases from 16.01 to 12.01 cN/tex and elongation decreases from 13.2% to 11.01%. At the same time, yarn production cost is reduced by approximately 21.4% when 50% soft waste is incorporated, confirming the economic feasibility of the proposed approach. Pearson correlation (statistical analysis) confirms an important relationship (correlation) between process waste percentage and yarn properties. Moreover, the study utilizes the MOORA (Multi-objective optimization based on ratio analysis) method as a judgment tool to find the perfect yarn based on properties, cost, and waste generation. The study establishes a validated, industry-compatible, and scalable route for valorizing spinning soft waste into high-value composite yarns, contributing to circular textile manufacturing and supporting Sustainable Development Goal 12 on responsible consumption and production.