A novel approach to fabricate a random-oriented staple fibre yarn (RO-SFY) by using a nonwoven spinning system

Abstract

This study introduces a novel nonwoven strip spinning method that adapts the principles of paper yarn technology, utilizing nonwoven fabric strips to produce random-oriented staple fibre (RO-SF) yarns. This method is chemically free and provides a sustainable alternative to traditional yarn production processes. Spunlace nonwoven fabrics, including 40 g/m² and 60 g/m², were processed with varying twist levels (20, 40, 60, 80, and 100 turns/20 cm) to evaluate key physical properties such as diameter, breaking strength, elongation, and yarn tenacity. Regression analysis revealed strong correlations (R² > 0.85) between yarn properties and twist level/strip width. Additionally, k-fold validation was employed to assess the accuracy of predictive models, enhancing the reliability of the results. Yarn diameters ranged from 0.50 to 1.9 mm for H40 and 0.59 to 2.33 mm for H60, with strip tex values ranging from 114 to 468 for H40 and 122 to 618 for H60. The breaking strength and elongation values were not suitable for high-strength textile applications, particularly for nonwoven strips below 2 mm. This research underscores the potential of nonwoven strip spinning as a versatile, eco-friendly yarn production method capable of processing a wide range of fibers, including non-spinnable materials, while offering a sustainable, chemical-free alternative to conventional spinning techniques.