Plant-based polyester a soft revolution in textiles

From hand-spun natural fibers to mass-produced synthetics like polyester, textiles have come a long way. While polyester's strength and versatility made it a global favorite, its reliance on petroleum raised environmental concerns. Today, plant-based polyester fibers are rewriting the fashion narrative. Indeed, cotton, being a natural fiber, has always been a popular choice in the textile industry for its breathability, comfort, and biodegradability. However, in recent years, there has been a growing emphasis on organic cotton and other sustainable cotton farming practices. Now, there is a here's a new fiber in the textile game, that’s blurring the lines between comfort and performance. Cotton-like polyester is an emerging trend that combines the best of both worlds: the softness and breathability of cotton with the wrinkle-resistance, durability, and moisture-wicking properties of polyester. This innovative material is poised to revolutionize the way we dress, offering a new level of comfort and practicality in everything from athleisure to everyday wear.

Polyester's reign and rise of microfibers

Invented in the 1940s, polyester quickly dominated the market. Its wrinkle-resistant, durable nature made it ideal for clothing and home furnishings. The emergence of microfibers further enhanced its appeal, leading to its integration in high-performance sportswear and luxurious silk-like fabrics.

Recycling revolution and the quest for sustainability

 While convenient, polyester's environmental footprint drew criticism. Plastic water bottles were reimagined as recycled polyester (rPET), offering a greener alternative. Brands like Patagonia and Marks & Spencer embraced rPET, paving the way for a more sustainable future.

Plant-based polyester

Breaking Free from Fossil Fuels: To truly reduce the industry's carbon footprint, a shift away from petroleum-based materials was necessary. Plant-based polyester, derived from sugarcane and corn, offers similar performance without the environmental baggage.

Why opt for plant-based polyester

• Unprecedented Comfort: It’s soft, breathable, and lightweight, these fabrics drape like a dream, offering the gentle caress of cotton without the static cling.
• Enhanced Moisture Management: Clammy polyester shirts are passé, cotton-like polyester wicks away sweat efficiently, keeping the wearer cool and dry during workouts or hot summer days.
• Wrinkle Resistance: This fabric retains its shape beautifully, making it perfect for travel and busy lifestyles. It’s just wash and wear, so ironing not really needed
• Easy Care: Forget hand-washing and delicate cycles. Cotton-like polyester is machine-washable and dries quickly, saving time and energy.
• Sustainable Potential: Many versions are made from recycled polyester, reducing reliance on virgin materials and minimizing environmental impact.
• Fashion Versatility: From casual tees to sleek athleisure, cotton-like polyester is finding its way into every corner of our wardrobes. Its versatility allows for endless design possibilities.

Applications and use

This trend is finding traction across various clothing categories viz:

• Activewear: Workout clothes feel luxuriously soft but don't leave a person drenched in sweat.
• Travel wear: Pack light with wrinkle-free clothes that transition seamlessly from sightseeing to dining.
• Casual wear: Enjoy the comfort of cotton without sacrificing shape or easy care.
• Formal wear: Look sharp and polished with wrinkle-resistant shirts and dresses that don't feel stiff or synthetic.

The Future Gazing

Cotton-like polyester is more than just a trend; it's a paradigm shift. This innovative material is just the beginning. As technology advances, one can expect to see even more sophisticated cotton-like polyesters with better properties. Developers are constantly innovating to make cotton-like polyester even softer, more breathable, and more sustainable. Expect to see this trend move beyond sportswear and into everyday clothing lines. This trend has the potential to transform the way we think about clothing, offering a new level of comfort and functionality that caters to our increasingly active and demanding lifestyles. And as production scales up, the cost is likely to decrease, making this material more affordable for everyone.

Major global manufacturers

As cotton-like polyester gains traction, several manufacturers are leading the charge. Here are some key players:

• Hyosung (South Korea): One of the biggest names in textiles, Hyosung offers various cotton-like polyester options under their Creora brand. These include: Coolmax EcoMade, a recycled polyester with a cotton-like touch, and Creora® Fresh with built-in odor control. They have a global presence with manufacturing facilities in Asia, Europe, and the Americas.
• Lenzing (Austria): Renowned for their Tencel and Modal fibers, Lenzing also offers Lenzing Ecovero, a sustainable viscose fiber with a cotton-like feel. They have a strong commitment to sustainability and offer various certifications for their products.
• Asahi Kasei (Japan): Known for their innovative materials, Asahi Kasei's Roica Eco Soft yarn utilizes recycled polyester to create a soft, cotton-like feel. They focus on performance fabrics and offer various stretch and shape-retention properties.
• Invista (US): Offers Coolmax Eco Soft, a recycled polyester fiber with a cotton-like hand, ideal for activewear and sportswear. They have a wide range of products across various applications, from apparel to bedding.
• Unifi (US): Pioneers in recycled and regenerated fibers, Unifi's Repreve recycled polyester can be engineered to achieve a cotton-like touch. They are committed to sustainability and offer various certifications for their recycled materials.
• Other Manufacturers: Toray (Japan) with their Primeflex Micro and Dermizax EV; Teijin (Japan) with their Eco Circle recycled polyester series; Wellspun (India) with their EcoSpun recycled polyester; Trevira (Germany) with their Biobased and Recycled polyester options. DuPont (US) produces Sorona fiber jointly with Teijin. Sorona offers a cotton-like feel and is a plant-based alternative to traditional polyester; Freudenberg Performance Materials (German) offers Hydroloft Eco fiber, made with recycled polyester and designed to mimic the softness and comfort of cotton. This list is not exhaustive as there are  other players globally active in this space

Towards a greener future for textiles

With its durability and ease of processing, plant-based polyester holds immense potential. From automotive interiors to high-performance sportswear, its applications are vast. As more players in the industry join the movement, the textile market is poised for a transformative shift towards a more sustainable future.