Read the label on any item of clothing and there is a good chance that polyester will be in it. But is polyester fabric safe to use?
Polyester - it is everywhere! Read the label on practically any item of clothing you buy, and there's a good chance that synthetic material will make an appearance. But is polyester fabric safe to use? Or does it harbour some potential hazards? Some people are concerned about the issue of toxic chemicals in polyester and their potential effects on health and the environment. “Is polyester bad for you?” is the question we address in this post. As you’ll discover, polyester can be hazardous under certain conditions. For instance, wearing polyester fabric has been linked to an increased incidence of flare-ups of dermatitis and acne. However, the overall degree of toxicity is likely low for most people.
What Is Polyester?
Polyester is not a natural fabric (like wool or silk). Unlike traditional natural materials such as cotton, linen, or wool, polyester is entirely man-made and does not offer the same breathability or environmental benefits. Instead, manufacturers make it from petroleum oil extracted from the ground. Like so many other synthetic products, it is popular because it is cheap. Polyester is one of the most widely used synthetic materials in the textile industry, valued for its durability and low cost. However, polyester is derived from petroleum, which contributes to environmental destruction from the outset of its production. Brands can make fabrics from components of crude oil more affordably than from more labour-intensive sources.
Technically speaking, polyester is a type of man-made plastic. For this reason, it takes a long time to break down, ranging from 20 to 200 years, depending on who you ask. Polyester does not biodegrade and can persist in the environment for up to 200 years, resulting in long-term pollution issues. Unlike natural fibres, which decompose relatively quickly and return to the environment, polyester persists and contributes to microplastic pollution.
Pure polyester has an almost rubbery feel, which sets it apart from the natural fibres you encounter. Usually, garment makers don’t use 100 per cent polyester but instead mix fibres to make items feel more like regular clothing. Thus, labels on fabrics will usually indicate something like 80% polyester, 20% cotton. (The higher the quality of the fabric, the less polyester the manufacturer will use.) In addition to blends of natural and synthetic fibres, there are also semi-synthetic fabrics, such as rayon and viscose, which are derived from plant sources but undergo significant chemical processing.
Types of Polyester
Polyester is not a one-size-fits-all material—there are several types, each with its own set of characteristics and uses in the textile industry. The most common form is Polyethylene Terephthalate (PET), which is widely used in everything from polyester clothing and home textiles to packaging materials. PET is valued for its strength, wrinkle resistance, and easy care, making it a staple in both fashion and household products.
Another type, Polybutylene Terephthalate (PBT), features a slightly different chemical structure that gives it unique properties. PBT is often used in technical applications, such as electrical components and automotive parts, due to its durability and resistance to wear.
Polytrimethylene Terephthalate (PTT) is a newer addition to the polyester family, prized for its elasticity and resilience. This makes PTT especially popular in activewear and sportswear, where stretch and recovery are essential.
A growing trend in the fashion industry is the use of recycled polyester, which is made from post-consumer waste, such as plastic bottles. By transforming discarded plastics into new polyester fibres, recycled polyester helps reduce landfill waste and conserves resources compared to virgin polyester. While recycled polyester shares many properties with its conventional counterpart, it offers a more sustainable alternative for eco-conscious consumers.
Understanding the different types of polyester can help you make more informed choices, whether you’re shopping for everyday polyester garments or seeking out sustainable options, such as recycled polyester.
How Do Manufacturers Make Polyester From Polyethylene Terephthalate?
Polyester was a fabric first developed in the 20th century by E.I. du Pont de Nemours and Co. The company wanted to know whether it was possible to make very long plastic fibres from petroleum derivatives. Under the leadership of chemist W.H. Carothers, the firm made some significant progress, developing nylon fibres in the 1930s. By 1946, DuPont purchased the rights to produce and sell polyester fabrics in the United States and, in 1951, began selling them under the trade name Dacron. The manufacturing process of polyester involves several steps, including refining raw materials, chemical reactions, and spinning fibres, which have significant implications for both product quality and environmental impact.
There are two main versions of polyester on the market today. The first is regular PET - the more popular type. It’s strong, elastic and resilient, making it popular for clothing. The other is PCDT. Brands typically weave this into thicker sheets and then market it for heavy-duty applications, such as draperies or furniture coverings.
To produce polyester, manufacturers first gather the necessary materials. The primary ingredient is ethylene, a hydrocarbon derived from petroleum. Ethylene molecules are the basic building block that gets converted into polyester strands during the chemical reaction known as polymerisation, which transforms raw materials like ethylene glycol and terephthalic acid into the PET polymer.
To manufacture a filament yarn, manufacturers react dimethyl terephthalate with ethylene glycol and a catalyst at high heat. They then warm the resulting compound to a slightly higher temperature and combine it with terephthalic acid to form a new polyester. A machine then extrudes it into ribbons and prepares it for the drying process. During this process, polyester fabrics shed microplastics when washed, contributing to plastic pollution in oceans and waterways.
Once dry, manufacturers cut the polyester into chips and melt it to form a syrupy solution. They then place the chips in a machine called a spinneret, which has tiny holes in it, and rotate the solution at high speed. During this stage, manufacturers may add additional chemicals, such as fragrances, fire retardants and other potentially toxic substances. The chemicals used in this stage can include stabilisers, antistatic agents, and lubricants to enhance the properties of the fibres. Various chemicals are also applied during production and finishing to achieve desired fabric characteristics, which can impact both health and the environment. As the mixture spins under heat, polyester begins oozing out of the holes. The centripetal force generates long filaments, forcing all of the molecules in the substance to align. This alignment gives polyester its unique combination of strength and flexibility. As the fibres dry, they become strong and resilient, not brittle as before.
While the process may sound complicated, spinning polyester is actually a relatively straightforward process. Once it took off in the US after 1951, dozens of manufacturers began using the material worldwide, including in Australia. Polyester became the fabric of choice in the 1960s, particularly for individuals seeking machine-washable napkins and tablecloths. The global spread of polyester production has led to the establishment of numerous polyester manufacturing plants, which have a significant environmental footprint due to their energy use, emissions, and waste.
Since then, though, polyester has been dealing with a negative image. In the past, consumers disliked its tacky appearance. However, the primary concern now is the potential impact it could have on human health. Heavy metals are sometimes present in the dyes and chemicals used in polyester production, posing health risks to consumers and contributing to environmental pollution.
During dyeing and finishing, special binders and polymers are used to help dyes stick to polyester fibres, ensuring colourfastness and resistance to fading.
Overall, the production processes for polyester involve multiple steps, each with its own set of chemical reactions, energy requirements, and environmental or health impacts.
The Toxicity Of Polyester
Unfortunately, polyester might not be safe. Different lines of enquiry are all converging on a negative view of the fabric, making the case against it stronger than ever. Concerns have been raised about exposure to toxic chemicals used in the production and finishing of polyester fabrics. Polyester can contain hazardous substances that may pose risks to both human health and the environment. For example, wearing polyester underwear has been linked to decreased sperm count and motility. These issues highlight the potential health risks associated with exposure to polyester.
Polyester May Release Irritant Chemicals Into Your Environment When Heated
Drying polyester fabrics in a dryer could be potentially hazardous. The application of heat may enable the outgassing of harmful chemicals, such as formaldehyde. The same may happen at night when the body comes into contact with bedsheets. Sleeping on synthetic bedding may release harmful chemicals, such as perfluorochemicals, into the air, which the skin then absorbs. Additionally, polyester clothing can release harmful chemicals, such as antimony, when exposed to heat. Evidence from animal studies suggests a causal link between exposure to perfluorochemicals through the skin and damage to the liver, kidneys, and reproductive systems.
Polyester May Release Carcinogens
The way some manufacturers process polyester fabrics may also create issues. As discussed in the previous section, some manufacturers add chemicals to polyester to enhance its blending properties with cotton, such as formaldehyde and ammonia. Both these chemicals are irritants and may exacerbate asthma symptoms. Furthermore, the EPA classifies formaldehyde as a possible carcinogen based on numerous lab reports and human trials. The organisation believes that it may increase the likelihood of myeloid leukemia.
Formaldehyde at air levels higher than 0.1 parts per million is associated with a range of less severe (yet distressing) health conditions, too. People exposed to the chemical can experience nausea, wheezing, skin irritation, coughing, watery eyes and burning sensations in the throat. Chronic inflammation caused by polyester can lead to various health issues, including arthritis and heart disease.
Some manufacturers add Teflon to polyester to help it retain its crinkle-free appearance after washing. Unfortunately, these too may make it carcinogenic. Teflon is a type of perfluorochemical that allows manufacturers to offer strain-free and wrinkle-resistant clothing. However, research indicates that it can enter the body and accumulate over time. Evidence suggests that it may cause serious health concerns such as liver and kidney damage, plus reproductive health issues.
Lastly, polyester fabrics usually contain the carcinogen, antimony. Labs regularly detect antimony residues in around 80 to 85 per cent of polyester fibres because manufacturers use it as a catalyst in the production of polyethylene terephthalate - the substance that they then extrude into yarn. Antimony remains embedded in the material and, according to research, may cause respiratory irritation, pneumoconiosis, antimony spots on the skin and gastrointestinal symptoms.
Polyester Exposure May Cause Allergies
Some people's skin can suffer an allergic reaction when it comes into contact with polyester - a condition known as contact dermatitis. Researchers believe that this occurs because some polyester fabrics contain toxic compounds. Additionally, polyester can trap sweat and bacteria against the skin, leading to irritation and infection.
Signs of allergic reactions to polyester include contact dermatitis, itchiness, skin redness and dryness, and abnormally warm skin. Individuals with severe reactions may experience hives or blisters on their skin. They may also experience breathing issues or sensations of tightness in the chest alongside pain.
Typically, the symptoms of an allergic reaction to polyester appear within minutes. However, they may take several days to appear in some cases.
Is Recycled Polyester Safer?
Given the alleged health problems associated with regular polyester, many people are wondering whether recycled varieties are any better. Today, the eco-fashion industry is advertising their products as containing recycled PET-based polyester fabrics.
Most recycled polyester comes from recycled PET plastic bottles. Processing plants crush the bottles and then cut them into tiny pieces, melt them down and then extrude yarn in much the same way as described above. Microplastics from polyester can enter the food chain through marine life, as fish ingest these particles. This contributes to microplastic pollution, which poses significant environmental and health risks as these particles contaminate water systems and food chains.
In general, it is an eco-friendly choice because it reduces waste and pollution by a small amount. However, because it relies on virtually identical processes as before, it remains harmful to both the individual human body and the Earth. The environmental impact of polyester remains significant, as its production and disposal continue to contribute to resource consumption, pollution, and non-biodegradability. Recycled polyester is made from plastic bottles, which helps reduce waste, but it still retains some of the environmental impacts of virgin polyester.
In fact, in some cases, recycled polyester may be more harmful. That’s because fabrics may contain Bisphenol A (BPA) from plastic bottles that contain the substance. The production of new clothing from recycled polyester continues to contribute to environmental issues, including the use of chemicals and the release of microplastics. Mayo Clinic reports that BPA exposure can lead to problems with the brain and prostate glands of children, raise blood pressure and increase the risk of diabetes and heart disease, particularly when exposed to heat.
Polyester bedding can also pose risks, as it may be treated with chemicals and lack breathability, which can potentially affect sleep quality and overall health.
Certifications and Labels: How to Identify Safer Polyester Fabrics
When it comes to choosing safer polyester fabrics, certifications and labels can be your best guide. These marks indicate that the polyester textiles you’re buying have been tested for harmful chemicals and produced with environmental and social responsibility in mind.
One of the most widely recognised certifications is OEKO-TEX, which ensures that polyester fabrics have been tested for a wide range of harmful substances. Products with this label meet strict safety standards, giving you peace of mind about what comes into contact with your skin.
For those seeking even higher standards, the Global Organic Textile Standard (GOTS) is a leading certification for organic fabrics. While GOTS is most commonly associated with natural fibres like organic cotton, it also covers polyester blends, ensuring that the entire textile production process meets rigorous environmental and social criteria.
The Bluesign label is another important certification, focusing on sustainable and environmentally friendly production methods. Polyester fabrics with the Bluesign label are made with reduced resource consumption and minimal use of hazardous chemicals, making them a safer choice for both people and the planet.
In Europe, the REACH regulation (Registration, Evaluation, Authorisation, and Restriction of Chemicals) ensures that polyester and other synthetic fabrics comply with strict rules regarding the use of chemical substances in textile production. Fabrics that meet REACH standards are less likely to contain toxic substances that could pose risks to human health.
By looking for these certifications and labels, you can make more informed decisions and choose polyester products that prioritise safety, sustainability, and responsible textile production.
Regulatory Framework: How Polyester Safety Is Governed
The safety of polyester fabrics is not left to chance—various regulatory frameworks and standards are in place to protect both human health and the environment throughout the textile production process. These regulations differ by region but share a common goal: to minimise exposure to toxic substances and ensure the responsible manufacture of polyester textiles.
In the European Union, the REACH Regulation sets comprehensive standards for the use of chemicals in textile production. This regulation requires manufacturers to register and assess the safety of chemical substances used in polyester fabrics, helping to prevent the use of hazardous chemicals that could harm consumers or the environment.
In the United States, the Toxic Substances Control Act (TSCA), overseen by the Environmental Protection Agency (EPA), regulates the use of chemicals in manufacturing, including those used in the production of polyester. TSCA aims to ensure that polyester textiles do not pose unreasonable risks to human health or the environment.
On a global scale, the ISO 14001 standard provides guidelines for environmental management systems, encouraging textile manufacturers to minimise their ecological impact during polyester production. Meanwhile, ISO 9001 focuses on quality management, ensuring that polyester fabrics meet consistent safety and quality standards.
These regulatory frameworks work together to ensure that polyester fabrics are produced responsibly, with careful attention to the use of toxic substances and the protection of human health. By understanding these standards, consumers and industry professionals alike can better navigate the complex world of synthetic fabrics and make more informed, safer, and sustainable choices.
What To Use Instead Of Polyester
Are there any alternatives to polyester you can use? Fortunately, there are.
If you are worried about polyester sheets outgassing during the night, replace them with cotton or silk alternatives. Cotton is the least expensive option and feels good on the skin. It is breathable and biodegradable because it comes from the cotton plant. Natural fabrics, such as cotton and silk, are healthier and more environmentally friendly choices compared to synthetic options.
If possible, opt for organic cotton products. These reduce the risk of exposing yourself to potentially harmful herbicides and pesticides. They also use vastly less water and energy to rear than their conventional counterparts. Certified organic cotton is also non-toxic, ensuring your bedding is free from harmful chemicals.
Hemp is another popular option that has been cultivated for thousands of years worldwide. It is one of the most sustainable materials available because it requires very little water to grow. Organic versions also tend to thrive, allowing them to produce around twice as much yarn per hectare as cotton. It’s breathable, renewable and feels similar to linen against your skin. Hemp and silk are excellent non-toxic alternatives to synthetic fabrics.
Silk is less affordable, but generally even more comfortable than the natural options discussed so far. It’s natural, biodegradable and renewable, but because it comes from insects, it’s not vegan.
However, if you still want silk and don’t want to harm animals, then you might want to opt for so-called ‘Ahimsa silk’ or ‘Peace silk’ since these are cruelty-free. Note that when manufacturers produce silk ethically and sustainably, it significantly reduces waste and increases energy efficiency.
Lastly, you might want to experiment with adding more linen to your collection. Linen comes from the flax plant—the same crop from which we obtain flaxseeds and flaxseed oil. Wearing it feels similar to both hemp and cotton. It has a slightly abrasive but robust feel on the skin - something that most people find familiar. Linen and flax are considered sustainable alternatives, making them eco-friendly choices for clothing and bedding.
Hardly any of the flax plants go to waste. Manufacturers use it to make paper, biomaterials, oils and other types of upholstery.
When selecting alternative fabrics, double-check to ensure they do not contain any polyester. As discussed, manufacturers often blend polyester with other materials to reduce costs and enhance product durability. For semi-synthetic fabrics like viscose and rayon, the fibres are derived from wood pulp, providing a renewable resource for fabric production.
Is Polyester Fabric Safe? A Final Note
In this article, we have highlighted all the evidence against using polyester as a fabric, pointing out the potential ways it may harm you. However, it is worth noting that the vast majority of people come into contact with the fabric every day of their lives with no ill effects. Polyester is not as hazardous as smoking, living a stressful life or eating junk food.
If you can avoid heating polyester in the dryer, that helps improve safety even more. Those who are worried should wear non-polyester-containing clothes and switch to cotton or silk bedding. If you do have polyester upholstery in your home, use it for fabrics that are unlikely to get hot, such as drapes. For items like, especially in homes with children, it’s also worth reviewing bean bag chair safety tips to ensure both material and design choices support a safer living environment.
Please note that changing your habits will incur some costs. Manufacturers use polyester because of the benefits that it brings to consumers. They aren't deliberately trying to hurt people (most of them aren’t even aware that there is a problem).
Polyester, for instance, is durable and lightweight. This allows manufacturers to cut product and shipping costs. It’s also highly wrinkle-resistant, meaning that you don’t need to iron it. You can just leave it out to drip dry, and you’ll have a perfectly smooth shirt.
Colours also tend to look more vibrant on polyester garments. So if you want to buy something colourful, polyester is often the best substrate.
Furthermore, garments made from polyester tend to retain their shape better. Fitted shirts can withstand multiple washes and still accentuate the wearer's physique.
Finally, there’s the fact that polyester is stain-resistant and, therefore, easy to clean. Compounds don’t easily become embedded in the fabric’s fibres, often washing out at low heat. Find out how to clean oil-based stains from polyester
In summary, therefore, polyester isn’t necessarily bad. Like most things, it comes with costs and benefits. If you choose to use the material, you can make your life more convenient. However, you may also be exposing yourself to harmful chemicals. It’s important to understand that no fabric is truly chemical-free—every material contains chemicals in some form. When considering 'chemical free' claims, consumers should be aware of what this actually means and make informed choices based on their own needs and concerns.
