Comprehensive assessment of fragmented fiber shedding from recycled cotton textiles. Part III integrated qualitative and quantitative assessment of released fibers and particles from woven textiles

Fragmented fiber release from textiles represents a growing environmental concern, particularly for systems containing recycled cotton. This study presents the third integrative stage of a systematic investigation linking fiber quality, yarn parameters, and woven fabric construction to the emission of fiber fragments and particulate matter during repeated laundering. Three mechanically recycled cotton blends (B, C, D) were processed into 29.5 tex rotor-spun weft yarns and woven with high-quality Egyptian combed cotton warps under industrial conditions. For all yarn variants, two dye shades (light and dark) were applied to introduce controlled color patterning in warp and weft directions of the woven structure. Fabrics underwent five simulated laundering cycles using the AHIBA apparatus under intensified mechanical agitation conditions, and released contaminants were quantified using image analysis.The number and size of released impurities were evaluated. Feret-based descriptors were used to characterize particle types, classified into two subgroups (dust and trash). Fiber-type impurities were further categorized into individual fiber fragments and bundles. Fiber fragment length was evaluated, as well as the maximum representative lengths of fiber structures using skeleton-based analysis. Results indicate that weft yarn quality and yarn state (gray vs. dyed) affect the number and morphology of released impurities. Fabrics containing highly contaminated yarns (type B) showed the highest initial shedding, while subsequent cycles showed a decrease in readily detachable material and progressive fiber fatigue and fibrillation. Individual fiber fragments were categorized into ultrashort, short, and long subgroups. Statistically significant differences among experimental groups were confirmed by Kruskal–Wallis tests ( p < 0.001).The estimated representative maximum lengths of fiber fragments (3,044 µm for l max branch and 261.75 µm for l fibre bundles ) complete the morphological characterization of fiber shedding.A systems-level approach linking fiber quality, yarn parameters, and fabric construction enables a hierarchical assessment of fragmented fibers and particle release across fiber, yarn, and fabric levels within recycled cotton textile systems.