From waste to high-quality yarn:
Truetzschler contributing to the sustainable
use of cotton with IDF 2
The demand for clothing is
increasing worldwide – but the areas for cotton cultivation are
limited. Truetzschler contributes significantly to the
sustainable use of this valuable raw material with
future-oriented technologies that enable the production of
high-quality yarns from cotton waste.
Using your own
waste – a clever concept
One example of a successful sustainability
concept is Bakan Tex in Uzbekistan. The company was founded in
Tashkent in 2017 after the government decided to promote the
entire value chain around the domestic textile sector.
Bakan Tex produces first-class combed ring
yarn. In the process, the so-called comber noil, which contains
short fibres and neps that are undesirable in high quality
combed ring yarn, is combed out at the combers. As the fibres
have already passed through the blow room and over the cards, it
is a high-quality “waste”.
Comber noil is a recyclable raw material
which is used, for instance, in banknotes or hygiene products.
It can also be spun into excellent rotor yarns. This is made
possible by shortening the process through the use of Integrated
Draw Frames (IDF). To allow processing into a good yarn, the
fibre length can be significantly shorter thanks to the IDF. The
yarn is of excellent quality even if 100% comber noil has been
processed. Until now, this has not been possible without the
Interview with FT
Bakan Tex already uses this great
potential. In the subsidiary FT Textile, founded in 2019, a
rotor spinning mill which processes the noils of Bakan Tex is
operated with 250 employees. 22 IDF 2 produce the feed for 8640
rotors. In addition, the company invested in a recycling plant
to process blow room and carding waste by pressing the good
fibres into bales and processing it with IDF 2.
We spoke to Mr. Sekar Rajam (CEO of FT
Textile), Mr. Jaya Prakash (Quality Production Manager) and Mr.
Abdukayum Saidov (Director) about the advantages of the
shortened process with IDF.
What made you
decide to process your own noils with IDF2? What convinced you
of this concept?
FT Textile: At FT Textile we rely on OE
spinning. We use 100 % raw cotton, but also cotton mix with
waste (comber noil). This process allows excellent processing of
short fibres (fibre length 20.6 mm) into yarn.
What are the main
advantages of the shortened process for your spinning mill? Does
it open up savings potentials for you?
FT Textile: This process is particularly
suitable for us, since we can use short waste fibres produced
during combing without any problems, in addition to so-called
virgin cotton. This not only saves raw materials, but also
space, energy and personnel.
How much yarn do
you already produce with the shortened process? And how are your
future plans in this respect?
FT Textile: So far we have produced an
average of 450 tons per card. We produce yarn from Ne 10 to 36.
In the near future, we expect to produce at least 1,000 tons of
yarn with consistent quality from each card.
ratio do you use? And how much waste and raw cotton do you
FT Textile: We produce with three blending
ratios: The first blend consists of 100 % raw cotton, blend 2 of
80% cotton and 20 % waste. Blend 3 contains only noils.
How do you assess
the yarn quality? What do your customers say?
FT Textile: Excellent! We are extremely
satisfied with the quality. We have not yet received any major
complaints from our customers.
For which end
products are the yarns produced with the shortened process
FT Textile: Our customers mainly come from
the knitwear and woven fabric sector.
In your opinion,
what are the ecological advantages of this process?
FT Textile: The most important advantages
for us are the significant energy savings and the reduced space
requirement. Also important for us is the fact that we need less
personnel due to the simplified can transport.
How do you assess
the future significance of the shortened process?
FT Textile: We are convinced that the
shortened process will continue to be important for us.
process – a model for a more sustainable future
Our practical example illustrates the
particular advantages of the shortened process with IDF 2. Thus,
the current challenges of saving raw materials and energy are
met by us and our customers. In addition to FT Textile, the
shortened spinning preparation process is already used by other
customers to process their own comber waste into high-quality
and the environment
The demand for textiles and thus for
cotton products is growing steadily due to population growth and
increasing per capita consumption as a result of economic
prosperity. Cotton is cultivated worldwide on an area as large
as Germany. However, cotton production cannot be increased at
will, as agricultural areas are limited. In addition, the plants
require warm climatic conditions and an extremely large amount
of irrigation. Furthermore, they are treated with pesticides and
insecticides and thereby account for ten percent of global
pesticide and fertilizer consumption.
Cotton is therefore a highly sought-after
but also controversial raw material. That is precisely why
efficient use is necessary. This circumstance is countered on
the one hand by adding synthetic fibres to cotton, and on the
other hand by sustainable methods of utilising the raw material.
Since 2019, both the production and the
processing of sustainable cotton have been supported by the
Federal Ministry for Economic Cooperation in the countries of
Uzbekistan, Cameroon, Burkina Faso and India.
Existing platforms and initiatives
worldwide are integrated to increase sustainability in the
cotton industry. Among other things, training courses for
farmers on more sustainable cultivation methods are offered
within this framework.