Straw and recycled nonwovens as alternative cellulose sources for nonwoven materials

The textile and nonwoven industries are some of the largest and fastest growing industries in the world. However, they are also some of the major contributors to environmental pollution. Therefore, there is a need to develop more sustainable alternatives in the textile sector. The nonwoven industry faces challenges with the single-use nature of many of its products and the use of non-renewable raw materials. In light of these challenges, this study explores the possibility of alternative cellulosic raw materials for producing man-made cellulose fibres (MMCF) for nonwovens using the Ioncell technology. Specifically, straw pulp and recycled Lyocell-based nonwovens are examined. Various pretreatments are applied to remove additives and improve spinnability, such as NaOH and H₂SO₄ treatments. The treatments and spinning conditions are optimized using a monofilament spinning unit and fibres are then produced for samples with a larger multifilament spinning unit. The properties of the fibres, including tensile strength, elongation, and orientation, are evaluated. The results show that the fibres produced from the recycled nonwovens and straw pulp exhibit comparable properties to standard Ioncell fibres. The recycling process is successful in maintaining fibre quality, making it a promising alternative for MMCF production.