Sustainable yarn production with optimum performance properties of recycled polyester knitted fabric

Purpose The purpose of this study is to evaluate whether the combined use of recycled polyester fibers and a reduced number of drawframe passages can provide yarn and fabric performance comparable to conventional ring-spinning processes while improving sustainability. Specifically, the study investigates the potential of a single drawframe passage to maintain yarn and knitted fabric quality when recycled polyester is incorporated, while simultaneously reducing energy consumption, carbon emissions and material waste in ring-spun yarn production. Design/methodology/approach Ring-spun yarns of Ne 14/1 and Ne 24/1 were produced with recycled polyester contents of 20%, 30% and 40% using both single- and double-passage drawframe configurations. Corresponding knitted fabrics were manufactured from each yarn sample. Yarn and fabric performance properties were experimentally evaluated, and statistical analysis was conducted using ANOVA to assess the effects of yarn number, recycled polyester ratio and drawframe passage number. Energy consumption and material efficiency associated with drawframe configurations were also considered. Findings The results indicate that yarns and knitted fabrics produced using a single drawframe passage exhibit performance properties statistically comparable to those produced with a conventional two-passage system for most evaluated parameters. Additionally, eliminating the second drawframe passage led to reduced energy consumption, lower carbon emissions and decreased material waste. These findings demonstrate that combining recycled polyester fibers with a single passage drawframe configuration offers a technically feasible and more sustainable alternative for ring-spun yarn production without compromising product quality. Originality/value This study provides original insight by systematically examining the effect of drawframe passage reduction in ring-spun yarns containing recycled polyester fibers an aspect that has not been sufficiently addressed in previous literature. While recycled fiber content and yarn count have been widely studied, the role of drawframe passage number in balancing yarn quality, fabric performance and sustainability has remained unclear. By demonstrating that a single drawframe passage can deliver comparable yarn and fabric performance with reduced energy consumption and material waste, this study offers both scientific and industrial value for sustainable yarn manufacturing.