Optimization of Combined Pre-Treatment Process for Bleaching of Cotton Woven Fabric Using Box–Behnken Design

The conventional bleaching process for cotton woven fabrics is characterized by high consumption of chemicals, water, and energy, resulting in significant environmental impact through elevated energy use and wastewater discharge. To address these concerns and align with sustainable development goals, there is an urgent need for eco-friendly alternatives that minimize environmental footprint while maintaining fabric quality. This study presents the development and optimization of a novel one-bath pre-treatment process for cotton bleaching, employing the Box-Behnken design to enhance sustainability. The optimized process utilizes 32% hydrogen peroxide and 12% sodium hydroxide based on fabric weight, operating at 90°C. The application of the Box-Behnken design facilitated substantial reductions in chemical usage, energy consumption, and wastewater output. The results demonstrated notable improvements in fabric properties, with a whiteness index of 139.5, weight loss of 7.9%, and tensile strengths of 404.9 N (warp) and 259.5 N (weft). Moreover, fabric absorbency increased by 9.3% compared to conventional methods. The findings underscore the efficacy of the Box-Behnken design in optimizing a more sustainable and eco-friendly bleaching process, which not only significantly enhances fabric performance but also offers considerable environmental benefits. This approach presents a promising solution for the textile industry to achieve greener practices while maintaining high-quality standards.