Recycling of cotton textile waste: Technological process, applications, and sustainability within a circular economy

The textile industry is one of the largest contributors to global pollution, generating substantial greenhouse gas emissions and millions of tonnes of waste annually. Addressing this environmental challenge through innovative regeneration strategies and using textile waste, particularly cotton, has emerged as a critical focus for resource conservation and sustainable development. Recycled cotton fibers, characterized by their biodegradability, availability, and cost-effectiveness, hold significant promise as reinforcement materials in green composites, though further research is essential to understand and utilize their potential fully. This comprehensive review examines the various types and sources of cotton waste, including fibers, yarns, fabrics, and apparel, and explores the technologies, methods, processes, and equipment employed in their waste recycling process. The paper also discusses the environmental impact of cotton waste and highlights how life cycle assessment and recycling practices enhance sustainability within a circular economy framework. Besides, it systematically discusses mechanical, chemical, and biological recycling processes and the application of recycled cotton waste in developing sustainable, biobased composites and nonwovens for industries such as automotive, construction, agriculture, health and hygiene, furniture, sports, and packaging. Additionally, the paper addresses the technical challenges, trends, and issues in cotton waste recycling, as well as the economic and environmental opportunities it presents. By providing an up-to-date synthesis of cotton waste recycling technologies, management, and applications, this review serves as a valuable resource for researchers, policymakers, and industry stakeholders, promoting innovation and advancing circular textile production systems.