Sustainable hybrid yarns from pineapple leaf and recycled cotton fibers: A green manufacturing approach and quality assessment in open-end spinning

The increasing demand for sustainable materials in the textile industry has prompted the exploration of agrowaste fibers as alternative raw materials for circular production systems that convert waste into high-value products. This study demonstrates an eco-efficient approach to hybrid yarn manufacturing by blending pineapple leaf fiber (PALF), an agricultural residue, with recycled cotton fibers recovered from spinning waste using an energy-efficient open-end spinning process. The methodology involved fiber preparation, blending, and open-end spinning, followed by yarn quality characterization and a sustainability process snapshot (SPS) analysis to assess material circularity and process efficiency. The results showed that the open-end spinning configuration effectively accommodated heterogenous waste-based fibers while maintaining stable spinning performance. The produced PALF-cotton hybrid yarn achieved a stable count of 20 Ne, with an average tenacity of 9.9 cN/tex, yarn evenness (U%) of 15%, and a low imperfection index (IPI), indicating satisfactory yarn quality. The SPS analysis revealed approximately 80% circular material input, fiber utilization efficiency around 85%, and a 20%–30% reduction in energy demand compared to a standard ring-spun cotton system. These findings highlight the technical feasibility and environmental benefits of producing quality yarns from agricultural residues and recycled textile waste. The proposed approach offers potential applications in sustainable textile manufacturing by reducing reliance on virgin cotton, lowering energy consumption, and supporting circular economy strategies in yarn production. • Hybrid natural yarns were developed from pineapple leaf and recycle cotton. • The study supports cleaner production of eco-textiles from agrowaste sources. • A circular economy approach was applied using cotton waste. • Demonstrates energy savings up to 30% in open-end spinning operation. • Achieves material circularity rate of 80% with stable yarn performance.