Is Poly Cotton Safe or Toxic? Disclosing the Truth

Polycotton is widely utilized in the textile and apparel industries. Like most products nowadays, it can be harmful, but there are always numerous rules and standards that govern appropriate amounts of used chemicals to ensure safety. There is no unique toxicity associated with polyester-cotton blends.

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Poly Cotton Blend Composition

Poly cotton (also referred to as polycotton or poly-cotton), is a fabric composed of polyester and cotton fibers, which are blended together to form a single yarn.

The percentages of polyester and cotton in a blend might vary, but popular ratios are for example: 80% polyester / 20% cotton, 65% polyester / 35% cotton, and 40% polyester / 60% cotton. Exact composition also affects the properties of the fabric blend.

Polyester is a petrochemical-derived synthetic textile, whereas cotton is a natural fiber recognized for its breathability and softness. When combined, the two materials provide a number of advantages, including higher durability and improved liquid and wrinkle resistance as compared to 100% cotton. In my opinion, poly cotton fabric is particularly popular in the textile industry because of its low production cost, which allows producers to achieve pretty decent outcomes for less money.

Poly Cotton Safety Concerns

There are some concerns surrounding the use of chemicals in the production of poly cotton fabrics. Thousands of chemicals are employed during the fabric manufacturing process, and some of them can be harmful. Some of these chemicals are washable, but others might remain in poly cotton fabrics after washing.

There is no unique toxicity associated with polyester-cotton blends. However, because the production of these blends includes the production of two very different fibers, a broader range of chemicals might be used in the process.

Some chemicals are commonly used in the production of polyester fibers, while others are used in the production of cotton fibers, and others are common in the production of textiles in general.

Chemicals used can also be influenced by fabric properties. For example, because poly cotton blends are usually more wrinkle-resistant, formaldehyde or another chemical that improves wrinkle resistance is less likely to be used.

It should be emphasized that determining the proportions of compounds that are toxic and the long-term effects of chemicals in our clothing can be sometimes challenging.

The presence of these substances can be regulated differently in different states, and regulations must be constantly updated since new chemicals can be introduced during the various phases of textile manufacturing. Producers, for example, can use an unfamiliar substance in the process that later turns out to be potentially toxic.

Research on the actual content of harmful chemicals in clothes sold on the retail market is relatively limited, or focused on a small number of substances. The H&M Group and IKEA investigation of post-consumer textile waste sourced from various locations of the world in 2021 found 2.5% undesirable detections and less than 1% detections from the prohibited chemicals list.

In a 2012 Greenpeace research, several blends and new clothing items from various manufacturers were tested, and amounts of NPEs, amines, and phthalates were measured. Most poly cotton goods contained some NPEs (some had substantial amounts of NPEs), quantified amines were below the detection limit, and the presence of phthalates was more common in 100% cotton than poly cotton blends.

General Textile Safety Issues

Some of the concerns related to poly cotton safety are common for most of the textiles. This is a list of just some of the issues that could arise.

In some instances, textile dyes applied to polyester-cotton blends or other fabrics can be toxic.

-Aromatic amines. They may be present due to the use of AZO dyes, which can also be used on poly cotton blends. After a breakdown, AYO dyes can produce other chemicals. When using AZO dyes, there are methods to avoid the undesirable generation of aromatic amines.

Chemical finishes. There are also a variety of chemical finishes that can be used in the textile industry to improve fabric softness or to make it antimicrobial, flame-retardant, water-repellent, or stain-repellent. Some of these various chemicals might be toxic.

Flame retardants. Because poly cotton is considered a relatively flammable material, some flame retardants may be used in poly cotton clothing, furniture, or home décor. There are hundreds of different flame retardants, some of which have been shown to be harmful to human health and are therefore prohibited from use.

Chemicals associated with waterproofing, water repellency, or stain resistance. For example, perfluoroalkyl substances (PFAS) can be used as water and stain repellents. They can be used in waterproof rain clothing as well as other water-repellent or waterproof clothing items. PFAS are also utilized in footwear, carpeting, furniture, and even non-stick cookware. The poly cotton blend does not absorb water as much as completely natural materials. But it is not waterproof or water-repellent naturally. There are a variety of negative effects of PFAS, and some even doubt their actual efficacy. PFAS don’t break down, so they can accumulate in water or the human body. Some U.S. states prohibit them, and the number of states instituting bans is growing. Their use is also restricted in the EU.

Heavy Metals. Lead, cadmium, and chromium (VI), for example, can be present in natural fibers such as cotton or as a result of contamination during the manufacturing process, and high amounts of these metals can be harmful to human health. Heavy metal safe levels are strictly regulated.

Phthalates are substances that are largely employed as plasticizers in the production of soft, flexible, and durable plastics. This group consists of a wide range of substances. In developed countries, the use of phthalates is usually restricted in some way. They are typically used to soften ink on clothing prints.

Nonylphenol ethoxylates (NPEs) were once widely utilized in consumer laundry detergents, although they are sometimes still used in industrial laundry detergents. They can cause skin irritation, but they are more associated with environmental issues. Nonylphenol ethoxylates are banned in the EU, and their use is limited in the United States.

Benzothiazoles. Some studies revealed the presence of benzothiazoles in clothing items. Further investigation is required to determine the precise implications and permissible levels of exposure to this particular chemical.

Safety Issues Related to Cotton

Pesticides. In terms of chemicals that may be linked to cotton fiber, insecticides, biocides, and fungicides may remain on cotton fibers after the crop has been harvested and processed into garments. Textile manufacturers usually take steps to eliminate them.

Chlorine bleach. Chlorine bleach is used for whitening cotton in polycotton blend, and sometimes it can emit irritating harmful fumes. However, in most cases, it does not remain on polycotton fabrics, since later stages of production require adequate removal of chlorine bleach or other bleaching agents.

Safety Issues Related to Polyester

Skin irritation. Many chemicals are used in the polyester production process, and there are various types of polyester. Polyester is not skin-friendly and can irritate the skin, therefore a higher percentage of polyester in the poly cotton blend may not be the ideal option for persons with sensitive skin.

Bisphenol A (BPA). BPA is an additive in the manufacturing of synthetic materials like polyester and is known as an endocrine-disrupting chemical and can have other negative effects. One of the recent challenges concerning polyester, but also poly cotton, is that the elevated BPA levels in socks were detected in socks made primarily of polyester and spandex in 2021. BPA was not found in socks made mostly of cotton or other natural fibers.

Additional Safety Measures

When it comes to poly-cotton blend fabrics, basic precautions can help to limit potential dangers. Using only natural materials does not always guarantee safety. Choosing products with appropriate certifications is in my opinion the safest option.

Certifications

There are several certifications available to help consumers choose safer poly-cotton fabrics. These certifications establish certain textile production standards and ensure that producers follow responsible practices. Here are a few examples of important certifications:

Oeko-Tex® Standard 100: This certification ensures that the fabric has been tested and is free from harmful substances, and covers various aspects and phases of the manufacturing process. Oeko-Tex® also issued a general ban on the use of PFAS in textiles.
Global Organic Textile Standard (GOTS) is more focused on organic products (at least 70%), but also hazardous chemicals used in different stages. So some poly cotton blends, that are made dominantly from organic cotton can have this certificate.
Bluesign® standard also ensures safe textiles, including raw materials, chemical components, and resources.
The EU Ecolabel is the official European Union voluntary label for environmental excellence, that ensures limited use of substances harmful to health and the environment.

Other Safety Measures

Always wash new garments or other poly cotton items.
Avoid apparel with heavy prints.
Select products from respected companies that promote safety, environmental responsibility, and quality control, especially in relation to waterproof, water, or stain-repellent products.
Select socks made primarily of cotton or other natural fibers; smaller amounts of polyester or spandex may be acceptable.
Avoid goods with strong chemical scents.

Environmental Implications

Many of the chemicals used in the production of poly cotton textiles can have a negative impact on the environment. Both fiber production and subsequent processing can be harmful to the environment.

Cotton is a little better component than polyester since it biodegrades. Cotton, on the other hand, requires the use of pesticides, and growing and processing can be water-intensive.

However, poly cotton blends do not biodegrade completely like cotton, and shed microplastics like polyester.

Polyester, a petrochemical-derived synthetic material, has a complex environmental impact. Its manufacture emits greenhouse gases and requires a considerable amount of water. The exact global warming impact of polyester production depends on how it’s made.

Conclusion

In summary, poly cotton is a blend that cannot be deemed harmful to health as such, and there are numerous rules that govern appropriate amounts of certain chemicals used in the manufacturing process.

However, if you want to be extra cautious, you can always choose poly cotton products with additional certifications that ensure their safety, or take extra precautions.