Tumble Dryer Drum Speed Control for Reduction of Fiber Shedding from Cotton Fabrics

Mechanical stress during tumble drying significantly contributes to textile degradation and microfiber release into the environment. This study investigates fiber shedding from cotton textiles under varying tumble dryer conditions using a modified heat pump dryer equipped with an external air filtration system. By altering drum speed and rotation patterns, we evaluated the impact of mechanical action on fiber loss, drying time, and energy consumption. Both reduced (10 rpm) and increased (70 rpm) constant drum speeds significantly decreased fiber shedding compared to nominal operation (58 rpm), though they resulted in longer drying and higher energy use. For example, operation at 70 rpm reduced fiber mass by 77% but increased drying time and energy use by 34% and 35%, respectively. To address this trade-off, phased drum operation strategies were developed, achieving up to a 50% reduction in shed fiber mass with moderate increases in drying time (29%) and energy use (17%). Regression analysis revealed that the total number of drum rotations, integrating both drum speed and drying duration, is a strong predictor of fiber mass and energy consumption. These results provide valuable insights into optimizing tumble drying for cotton textiles to enhance their longevity and reduce the environmental emission of microfibers.