Polyester

Understanding Polyester: From Petrochemicals to Everyday Fiber

Polyester is one of the world’s most widely used synthetic materials, and its presence extends far beyond the clothing industry. Although we often think of it simply as a man-made textile, its story begins with petroleum, chemical reactions and decades of industrial innovation. Exploring how polyester is created reveals why it has become so dominant—and why its environmental impact raises important questions.

How Polyester Was Invented

Polyester was first developed in the early 1940s by two British chemists, who discovered how to create a plastic-like fiber from petroleum-based components. It reached the French market in the 1950s under the brand name Tergal®, becoming one of the earliest synthetic fibers to be commercialized, arriving after nylon but before acrylic and elastane.

Where Polyester Production Takes Place Today

Although it originated in the United States, polyester is now primarily produced in Asia. China leads global manufacturing and exports, while India and Pakistan also play major roles in the supply chain. These countries have become essential hubs for the large-scale, energy-intensive production of synthetic fibers.

How Polyester Is Manufactured

Turning petroleum derivatives into polyester fiber requires a sequence of complex chemical operations. The most common method is polycondensation, where two refined components of crude oil—terephthalic acid and ethylene glycol—react at high temperatures to form long molecular chains.

The resulting polymer is cooled into granules, then melted again to form sheets that are dried and broken into smaller pieces. These fragments are melted once more to create a viscous gel, which is pushed through a spinneret to form filaments. Depending on the final application, these filaments may be blended with additional chemicals before being spun into yarn and dyed for use in textiles.

How Polyester Is Used Across Industries

Polyester has become the dominant synthetic fiber globally. In 2021, production reached more than 60 million tonnes—representing roughly 80% of all synthetic fibers produced. Over the last 15 years, output has nearly doubled, and the material now appears in countless everyday products.

Polyester in Clothing and Home Textiles

Since the mid-2000s, polyester has overtaken cotton as the most widely used material in ready-to-wear fashion. Its low cost, durability and versatility make it suitable for nearly every item in a wardrobe: pants, dresses, shirts, T-shirts, swimwear, loungewear, jackets, underwear and sportswear. Brands also rely on polyester for more technical garments, especially activewear, where moisture-repellent and quick-drying properties are essential.

Beyond clothing, polyester is common in home essentials such as curtains, bedding, towels, microfibre cloths, table linens, carpets and decorative fabrics.

Other Uses Beyond Fashion

Many industries depend on polyester for its strength, elasticity and chemical resistance. It appears in:

• automotive components such as seatbelts, tires and resin-based body parts
• furniture padding and upholstery
• construction materials including insulation, tarpaulins and geotextiles
• PET plastic bottles and packaging
• toys, household items and decorative products
• LCD screens for computers, televisions, tablets and phones

Its adaptability, durability and low cost explain why polyester has become deeply integrated into consumer goods and industrial applications.

Why Polyester Remains So Popular

A Low-Cost Fiber

Affordability is one of polyester’s strongest advantages. It is cheaper to produce than most natural or synthetic fibers due to large-scale industrialization and low manufacturing costs in producing countries. In 2016, one pound of polyester cost around 43 cents, compared to roughly 70 cents for cotton. Though rising petroleum prices may eventually influence its cost, polyester remains one of the most economical fibers available.

Strong, Elastic and Versatile

Polyester is known for its exceptional durability. It resists heat, friction, stretching, shrinking and fading, giving garments a long lifespan and maintaining their shape. Polyester fibers do not attract mold or moths, and their elasticity contributes to comfortable, wrinkle-resistant clothing.

Because it does not retain moisture, polyester is widely used in sportswear. It dries quickly, performs well under thermal stress and offers wind- and water-resistant qualities appreciated in outerwear and rainwear. It also blends easily with other fibers such as cotton, wool and elastane, and accepts dyes without difficulty.

Easy-Care Fabrics

Polyester is highly resistant to washing conditions and can be cleaned at 30–40°C. It dries quickly in open air and typically requires no ironing. Care instructions remain simple even when polyester is blended with other fibers.

The Environmental Impact of Polyester

A Polluting and Resource-Heavy Material

Because polyester is derived from petroleum, its environmental footprint is significant. Producing synthetic fibers requires large quantities of non-renewable fossil resources. For example, manufacturing just two fleece jackets requires around 1.5 kilograms of crude oil.

The production process also relies on chemicals that may harm ecosystems, contribute to air and water pollution and threaten the health of workers and nearby communities. Energy consumption is considerable, especially in factories powered by coal or other polluting sources. Producing a single polyester dress can generate as much CO₂ as a 500-kilometre drive in a modern car.

During washing, polyester fabrics release microscopic plastic fibers that wastewater treatment plants cannot filter. These particles eventually enter rivers and oceans, becoming the leading source of microplastic pollution—surpassing plastic bags. Solutions such as the Guppyfriend washing bag can capture a portion of these fibers, and by 2025 all new washing machines in some regions will be required to include microplastic filters.

Polyester is also difficult to recycle. Many items end up incinerated, releasing harmful fumes, or are sent to open landfills where they contribute to global plastic waste accumulation. In 2015, polyester production emitted about 700 million tonnes of CO₂—equivalent to the annual emissions of Mexico.

A Fiber With Comfort Limitations

Although durable, polyester is not always comfortable to wear. Its coarse fiber structure can feel rough against the skin. Low absorbency causes moisture and perspiration to linger, leading to odor buildup. Sensitive individuals may also experience allergic reactions. Unlike wool or linen, polyester offers little insulation against the cold and is prone to static electricity, which is why blends such as polycotton are often used.

Recycled Polyester: Progress and Remaining Challenges

Recycled polyester, often abbreviated PET, has gained popularity as a more sustainable option. It is typically made from discarded PET bottles or ocean-collected plastic waste. These plastics are cleaned, shredded into chips, melted into polymer pellets and spun into new yarn. Approximately 54 bottles are needed to produce two fleece jackets.

Recycling reduces energy consumption by about 59% and lowers CO₂ emissions by roughly 32% compared to conventional polyester. It also gives a second life to materials that would otherwise require processing at the end of their lifespan.

However, recycled polyester still shares many of the limitations of virgin polyester: it requires chemical treatments, sheds microplastics during washing and is not biodegradable.

Some innovations aim to address these issues. In 2020, PrimaLoft® introduced a biodegradable insulation made from recycled polyester, engineered to be consumed by naturally occurring bacteria in soil and seawater. Early tests suggest this material can break down almost entirely in less than two years—a promising development for reducing polyester’s long-term environmental impact.