Potential of jute seeds crop waste for textile applications: a novel machine-based approach for sustainable resource utilization

Seed-producing jute plants are commonly harvested solely for their seeds, leaving the fibre-rich stems unutilized and often burned, which contributes to environmental pollution and resource loss. This study explores the valorization of these stems by extracting fibres suitable for textile applications while maintaining seed yield. A novel Circular Scissor machine was designed and fabricated to separate seed-bearing branches from fibre-rich stems with an operational efficiency of 65–100% and minimal seed damage. The separated stems were processed using two retting methods: biological (water) retting and a mixed biological–chemical retting process employing 5% urea. A side-by-side comparison showed that the urea-assisted process reduced the total retting time (from 33 to 29 days) and produced finer fibres (2.90 tex vs. 3.27 tex for water-retted samples), with improved surface cleanliness and better strand separation, as confirmed by SEM and FTIR analyses. Both methods yielded fibres that met Bureau of Indian Standards (BIS) grading standards for coarse textile applications such as rugs, mats, and upholstery. This combined approach preserving seeds while recovering fibre reduces open-field burning, enhances farmers’ income streams, and demonstrates the potential of jute seed crop stems as a sustainable textile fibre resource.