Cotton bleaching: evolution, current practices, and future perspectives

Abstract This manuscript explores the evolution, current practices, and future prospects of cotton bleaching, a vital process in textile manufacturing for achieving high whiteness and esthetic quality. It examines traditional methods, such as hydrogen peroxide and sodium hypochlorite bleaching, and their environmental drawbacks, including high water and energy consumption and chemical discharge. The study highlights sustainable alternatives—enzymatic, plasma, ozone, and nano-catalyzed bleaching—that reduce environmental impact, enhance fiber integrity, and align with circular economy principles like bleach bath reuse and cotton recyclability. By analyzing efficiency, cost, scalability, compatibility with textile blends and finishes, and adoption barriers, the manuscript offers a comprehensive comparison of these technologies. It projects potential reductions of 30% in water usage and 40% in carbon dioxide emissions by 2035 through eco-friendly innovations and closed-loop systems. Drawing on recent research, this work underscores the textile industry’s transition toward sustainable and circular production, providing insights for researchers, manufacturers, and policymakers to advance environmentally responsible bleaching practices.