Recycling of disposable single-use face masks to mitigate microfiber pollution

The effectiveness of disposable masks in mitigating the transmission of COVID-19 infection increased the consumption of masks. The cheaper cost and easy accessibility resulted in massive consumption and disposal of non-woven masks. The improper disposal of mask emits microfiber into the environment upon weathering. This research mechanically recycled the disposed-of masks and developed fabric from reclaimed polypropylene (rPP) fibers. Obtained rPP fibers were blended with cotton in different proportions (50/50, 60/40, 70/30 cotton/rPP) to produce rotor-spun yarns and evaluated for their performance. The results of the analysis revealed that the developed blended yarns have enough strength; however, they are inferior to the 100% virgin cotton yarns. Based on its suitability, knitted fabrics were developed from 60/40 cotton/rPP yarn. Along with the physical properties, the microfiber release behavior of the developed fabric was analyzed at its different phases of the lifecycle (wearing, washing, degradation at disposal). The microfiber release was compared with the release characteristics of disposable masks. The results showed that recycled fabrics could release 2.32 microfiber/sq. cm during wearing, 4.91 microfiber/sq. cm in laundry, and 15.50 microfiber/sq. cm at the end-of-life disposal by weathering. In contrast, the mask can release 79.43, 96.07, and 223.66 microfiber/sq. cm, respectively, for use, immediate disposal, and long-term disposal by weathering. Approximately, an 83.17% reduction in the microfiber release was reported when the masks were recycled into fabrics. The compact structure of fabric where the fibers are made into yarn resulted in lesser fiber release. Mechanical recycling of disposable masks is simple, less energy-intensive, less expensive, and can be quickly adopted. However, a 100% elimination of microfiber release was not possible in this method due to the inherent nature of the textiles.