Sustainable or recycled polyester, often known as rPET, is created by recycling old polyester fiber or plastic bottles into a new sustainable polyester fiber. What makes it sustainable and economical is its actual production process. Also, compared to fresh polyester its manufacturing process uses fewer resources and emits low CO2. Although it is still not biodegradable and takes a long time to decompose sustainable polyester fabric is indeed a good way to lessen the pollution caused by these plastics.

Types of Sustainable Polyester Fabric

We must deny that polyester is one of the most common fabrics being offered in the market. With that being said, most clothing lines, garments, textiles, and other industries that need fabric, highly use polyester in their product. In CoronadoFabrics, we offer many types of polyester. They are as follows:

• Polyester Organza fabric
• Polyester Taffeta fabric
• Imitation memory fabric
• Polyester Pongee fabric
• Polyester Peachskin fabric
• Polyester Taslan fabric
• Polyester Spandex fabric (including 4-way stretch)
• Polyester Oxford Fabrics
• Polyester Satin Fabric
• Polyester Conductive fabric (graphene)
• Polyester Corduroy fabric
• Polyester Yarn fabric
• Polyester Gabardine fabric
• Polyester T400-T800 (spandex, elastic fiber)
• Polyester Artificial Silk (art silk) fabric
• Polyester Mini Matt fabric
• Polyester Interlining fabric: 
• Sustainable & Recycled Polyester Fabric

History of Polyester Fabrics

Polyester was first invented in the mid-20th century by British scientists John Whinfield and James Dickson, who were trying to create a synthetic alternative to silk. They discovered that by combining ethylene glycol and terephthalic acid, they could create a strong and durable material that could be spun into fibers.

However, it wasn’t until the 1950s that polyester fabrics were commercially produced. In 1951, a team of researchers at the DuPont company developed a high-strength polyester fiber known as Dacron. This fiber was quickly adopted by the fashion industry, as it was less expensive than silk and could be used to make a variety of garments.

In the following years, polyester fabrics became increasingly popular, as they were more durable, easier to care for, and less expensive than natural fabrics like cotton and wool. Polyester was also used in a variety of industrial applications, such as in the production of tires, conveyor belts, and packaging materials.

During the 1960s and 1970s, polyester fabrics became a symbol of the “modern” age, as they were used to make a wide range of clothing and home decor products. However, by the 1980s, polyester fell out of fashion as consumers began to prefer natural fabrics again.

Today, polyester fabrics are still widely used in the textile industry, as they are affordable, durable, and easy to care for. However, there is growing concern about the environmental impact of polyester production, as it is a petroleum-based product that is not biodegradable. As a result, researchers are exploring new ways to make polyester fabrics more sustainable and environmentally friendly.

Manufacturing process of polyester fabrics

The manufacturing process of polyester fabrics involves several steps, including polymerization, spinning, and weaving or knitting. Here’s a brief overview of each of these steps:

1. Polymerization: The first step in making polyester fabric is to create the raw material, which is known as polyester resin. This is done by combining purified terephthalic acid (PTA) and monoethylene glycol (MEG) in a reactor vessel. The mixture is heated to high temperatures and pressurized, causing the PTA and MEG to undergo a chemical reaction that produces a clear liquid known as polyester resin.
2. Spinning: Once the polyester resin has been produced, it is then spun into fibers. This is done by extruding the liquid resin through a spinneret, which is a small metal plate with tiny holes in it. As the resin is forced through the holes, it cools and solidifies into thin strands of polyester fibers.
3. Weaving or Knitting: The next step is to weave or knit the polyester fibers into fabric. This is done using large machines that interlace the fibers to create a sheet of fabric. Weaving involves interlacing the fibers at right angles to create a strong, stable fabric. Knitting, on the other hand, involves interlooping the fibers to create a more flexible and stretchy fabric.
4. Finishing: Once the polyester fabric has been woven or knitted, it goes through a finishing process to improve its appearance and performance. This may include treatments to make the fabric softer, more wrinkle-resistant, or more water-repellent. The fabric may also be dyed or printed with a design at this stage.

Throughout the manufacturing process, specialized machinery and equipment are used to ensure consistent quality and efficiency. This includes extruders for spinning the polyester fibers, looms or knitting machines for weaving or knitting the fabric, and finishing equipment for treating and dyeing the fabric.

Applications of Polyester Fabrics

Polyester fabrics are versatile and widely used in a variety of applications across different industries. Here are some of the main applications of polyester fabrics:

1. Clothing: Polyester is commonly used to make clothing, such as dresses, pants, and shirts. It is a popular choice for sportswear and outdoor clothing because of its durability and moisture-wicking properties. Polyester can also be blended with other fibers, such as cotton or wool, to improve the fabric’s softness and breathability.
2. Home Textiles: Polyester fabrics are also used in a variety of home textiles, including curtains, upholstery, bedding, and carpets. Polyester fabrics are often used in these applications because they are easy to clean, resistant to stains, and durable enough to withstand everyday use.
3. Industrial Fabrics: Polyester is commonly used in industrial applications, such as conveyor belts, packaging materials, and geotextiles. These fabrics are used in harsh environments where high strength and resistance to abrasion are required.
4. Automotive Textiles: Polyester fabrics are used in the automotive industry for a variety of applications, including seat covers, carpets, and insulation materials. Polyester fabrics are ideal for these applications because they are durable, resistant to UV radiation, and can withstand high temperatures.
5. Medical Textiles: Polyester fabrics are also used in the medical industry for various applications, including surgical gowns, masks, and bandages. These fabrics are preferred due to their resistance to moisture, bacteria, and chemicals.

Overall, polyester fabrics are popular across many industries due to their versatility, durability, and ease of care. While there are some environmental concerns with the production of polyester, ongoing research and development are helping to create more sustainable alternatives.

Advantages and Disadvantages of Polyester Fabrics

Polyester fabrics have a range of advantages and disadvantages, which are important to consider when choosing them for various applications. Here are some of the main advantages and disadvantages of using polyester fabrics:

Advantages:

1. Durability: Polyester fabrics are known for their durability and strength. They are resistant to tears and abrasion and can withstand regular use and wear.
2. Easy maintenance: Polyester fabrics are easy to care for and maintain. They are typically machine washable and can be dried quickly.
3. Low cost: Polyester fabrics are relatively inexpensive compared to other fabrics, making them an affordable choice for a wide range of applications.
4. Versatility: Polyester fabrics can be made in a variety of weights, textures, and colors, making them versatile for many different applications.
5. Moisture-wicking: Polyester fabrics are moisture-wicking, which makes them ideal for use in sportswear and outdoor clothing.

Disadvantages:

1. Environmental impact: The production of polyester fabrics is resource-intensive and can have a negative impact on the environment. The production process consumes a large amount of energy and releases greenhouse gases.
2. Lack of breathability: Polyester fabrics are not as breathable as natural fabrics, such as cotton or wool. This can make them uncomfortable in hot or humid weather.
3. Static cling: Polyester fabrics are prone to static cling, which can be annoying and uncomfortable.
4. Prone to pilling: Polyester fabrics can be prone to pilling, especially when rubbed against other fabrics or surfaces.
5. Heat sensitivity: Polyester fabrics can be sensitive to high heat, which can cause them to melt or become damaged.

Overall, polyester fabrics have many advantages that make them a popular choice for a wide range of applications. However, it’s important to consider their potential negative impact on the environment and weigh their advantages and disadvantages carefully when choosing them for different uses.

Future of Polyester Fabrics

As concerns about the environmental impact of synthetic materials grow, researchers and manufacturers are exploring new technologies and innovations to make polyester fabrics more sustainable and environmentally friendly. Here are some of the ways the future of polyester fabrics is being shaped:

1. Recycled polyester: Recycled polyester is made from post-consumer waste, such as plastic bottles. It is becoming an increasingly popular alternative to traditional polyester fabrics because it reduces waste and conserves resources. The process of recycling polyester involves breaking down plastic bottles into small chips, which are then melted and spun into fibers.
2. Biodegradable polyester: Biodegradable polyester is a new type of polyester that can break down naturally in the environment. This type of polyester is made from plant-based materials, such as cornstarch, rather than petroleum-based materials. Biodegradable polyester is still in the early stages of development but has the potential to significantly reduce the environmental impact of polyester fabrics.
3. Sustainable production methods: Manufacturers are exploring new production methods to reduce the environmental impact of polyester fabrics. For example, using renewable energy sources, such as wind and solar power, to power production facilities can reduce greenhouse gas emissions. Additionally, closed-loop production processes that reuse and recycle water and chemicals can reduce waste and pollution.
4. Innovative designs: Designers and manufacturers are exploring innovative designs and applications for polyester fabrics to reduce waste and increase sustainability. For example, polyester fabrics can be used to create modular and adaptable clothing designs that can be easily repaired, reused, or recycled.
5. Increased transparency and accountability: Consumers are becoming more interested in the environmental impact of the products they buy, and manufacturers are responding by increasing transparency and accountability in their production processes. Certification programs, such as the Global Recycled Standard and the bluesign® system, help consumers identify sustainable and environmentally friendly products.

Overall, the future of polyester fabrics is likely to involve a combination of new technologies, sustainable production methods, and innovative designs to reduce their environmental impact. As consumer awareness grows, manufacturers will need to continue to find ways to make polyester fabrics more sustainable and environmentally friendly.