The textile industry is at a crossroads of performance and sustainability. With environmental concerns overhauling the current manufacturing priorities, recycled polyester has managed to come out as a strong competitor to conventional cotton. As the world is on track to reach a global recycled polyester market of $26.18 billion by 2030, the fabric is gaining its ground amongst such eco- and fashion-conscious giants as Nike, Patagonia, and H&M.
Will recycled polyester ever actually become the source of supply of cotton as the fiber of choice by the industry? The explanation can be found in the realization of the distinctive properties of each of the materials, as well as how these properties are going to change and define the future of sustainable textiles.
Understanding Recycled Polyester: The Sustainable Revolution
Recycled polyester fabric, commonly referred to as rPET, is an eco-conscious material forged from recycled plastics, notably used plastic bottles or polyester bottles, garments, and industrial plastic waste. This converts otherwise waste into high quality textile fibres.
Production of plastics involves the collection and sorting of items used in making plastics, cleaning them, shredding them into PET flakes, and melting them down into pellets. These pellets are spun into polyester staple fiber or filament yarn, creating recycled poly fabric that maintains the same performance characteristics as virgin polyester.
The Numbers Tell a Compelling Story
In 2008, approximately eight percent of the total polyester fiber in production was converted by using recycled materials around the world. In 2023, this value amounted to 13 percent. The momentum continues building as the industry recognizes recycled polyester's potential.
The 2025 Recycled Polyester Challenge calls on companies to commit to sourcing from 45% to 100% of their polyester from recycled sources by 2025. Such a lofty goal reflects the intentions of the textile sector to minimize its environmental impact.
Saheb Fibre: Driving Sustainable Innovation in India
Saheb Fibre has emerged as a trusted name in the recycled polyester industry, specializing in RPSF, PET flakes, and colored recycled polyester staple fiber. By combining advanced recycling technology with a commitment to sustainability, Saheb Fibre supplies high-quality materials to textile manufacturers across India and abroad, enabling brands to reduce their environmental footprint while driving innovation in polyester sustainable solutions.
Environmental Benefits: Why Recycled Polyester Shines
Energy Efficiency and Carbon Reduction
Recycled polyester is almost the same as virgin polyester in terms of quality, but its production requires 59% less energy compared to virgin polyester. Manufacturers of recycled polyester fabric aim to reduce CO2 emissions by 32% in comparison to regular polyester.
This significant energy reduction makes recycled polyester clothing an attractive option for environmentally conscious brands seeking to lower their carbon footprint.
Waste Reduction and Resource Conservation
Recycled polyester textile gives a second life to a material that's not biodegradable and would otherwise end up in a landfill or the ocean. We can change this by thinking about five bottles of water: they contain sufficient fibre to manufacture a single t-shirt.
The effects on the environment extend beyond the minimization of wastes. Using recycled polyester lessens our dependence on petroleum as a source of raw materials, helping preserve finite fossil fuel resources.
Water Conservation Advantages
Unlike cotton cultivation, which requires substantial water resources, recycled plastic fabric production from post-consumer waste uses significantly less water. Such an advantage is essential in the context of the water scarcity in the textile production global areas.
Cotton's Enduring Appeal and Challenges
Cotton is still popular with its natural qualities, which are breathability, softness and biodegradability. Cotton fibers are naturally biodegradable, which reduces the amount of impact its garments can make on landfill waste.
The cultivation of cotton, however, has significant effects on the environment in terms of water intake, pesticide use, and the territory needed. It is because of these obstacles that many brands have tried to find alternatives whilst preserving the appealing qualities of cotton.
Is Recycled Polyester Fabric Better Than Cotton?
The comparison between recycled polyester and cotton isn't straightforward. Each material excels in different areas:
Recycled Polyester Advantages:
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Lower energy consumption during production
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Diverts plastic waste from landfills and oceans
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Durability and wrinkle resistance
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Color retention and quick-drying properties
Cotton's Strengths:
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Natural breathability and comfort
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Biodegradability at end-of-life
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Renewable resource when grown sustainably
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Consumer preference for natural fibers
Comfort & Wearability: Cotton vs. Recycled Polyester
When speaking about daily-wear items, sustainability is not everything; comfort and wearability may become priority criteria in consumer decision-making. Many people ask: “Is recycled polyester as comfortable as cotton?” This varies according to the performance aspects.
1. Skin Feel
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Cotton: Being all-natural, soft and mild on skin, cotton fibers provide a smooth surface and are therefore suited when wearing them daily, as well as underwear and baby clothes.
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Recycled Polyester (rPET): Contemporary rPET fabrics are designed to feel soft and light, but they often do not have the soft, plushy texture of high-quality cotton. Blends with cotton or natural fibers tend to modulate the hand feel.
2. Breathability & Temperature Regulation
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Cotton: Fabric materials are not very thick, so it highly breathable as far as the natural fibers are concerned, which is quite suitable in warm environments and during summer seasons
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Recycled Polyester: Not as breathable, but it performs better in moisture-wicking to pull sweating moisture away. This is why activewear and performance apparel are made with rPET to a large extent.
3. Moisture Absorption
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Cotton: It can absorb up to 25 times the weight of water and this makes it keep skin cooler but results in prolonged drying.
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Recycled Polyester: Absorbs little moisture, dries quickly, and resists shrinkage, advantages for sportswear and travel apparel. Absorbs very little moisture, dries fast and will not shrink: that would suit sportswear and travel clothes.
4. Odor Retention
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Cotton: Natural fibers trap fewer odors and can be easily refreshed with washing.
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Recycled Polyester: More susceptible to the build-up of odors because bacteria are fond of growing on the synthetic fabrics, newer antimicrobial finishes are assisting in alleviating this problem somewhat.
5. Allergies & Skin Sensitivity
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Cotton: Hypoallergenic and rarely causes irritation, making it a safe choice for sensitive skin.
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Recycled Polyester: Safe, although some individuals whose skin is highly sensitive will find the synthetic fibers not comfortable in certain hot and humid climates.
Key Takeaway: Cotton wins in natural comfort and skin-friendliness, while recycled polyester excels in durability, moisture management, and quick-drying performance. It is because of this that most brands are converting to cotton poly blends in an attempt to give a consumer taste of the two worlds.
Performance Characteristics: Meeting Industry Demands
1. Durability and Longevity
With synthetic fabrics such as polyester, there is no loss of shape experienced on the fabrics, unlike cotton and consequently they have a longer life in the environment, thus they have less impact on the environment. This durability factor makes recycled polyester fiber particularly suitable for activewear and technical textiles.
2. Versatility in Applications
Recycled polyester staple fiber and filament yarn can be engineered for various applications, from lightweight summer clothing to heavy-duty industrial textiles. This versatility gives recycled polyester an edge in replacing cotton across multiple product categories.
Market Growth and Industry Adoption
1. Explosive Growth Projections
The global recycled polyester market size was estimated at USD 15.52 billion in 2024 and is projected to reach USD 26.18 billion by 2030, growing at a CAGR of 9.25%. This growth is an indication of growing demand in various sectors
The Global Recycled Polyester Filament Yarn Market was valued at USD 5.5 billion in 2023 and is projected to grow at a CAGR of 7.2% from 2024 to 2030.
2. Leading Brand Commitments
Major fashion brands are making substantial commitments to rpet polyester. Adidas made a pledge to use only recycled polyester in its products by 2024. Patagonia, a company that was an early mover in sustainability in its apparel, has been using rPET since 1993.
Conclusion: A Complementary Future
Can recycled polyester replace cotton in the textile industry? The evidence also proposes that it is not a complete substitution, but a strategy of complementarity. Recycled polyester excels in durability, performance applications, and environmental efficiency, while cotton maintains advantages in comfort, breathability, and biodegradability.
The future textile industry will likely feature increased use of recycled polyester in technical applications, activewear, and durability-focused products, while sustainable cotton maintains its role in comfort-oriented apparel. Both materials play an important role in the development of a more sustainable textile system.
As technology advances and consumer preferences evolve, recycled polyester will undoubtedly capture a larger market share. But in place of entire replacements, the industry is shifting towards smart material choices to meet the demands of applications, sustainability objectives, and consumer preferences.
The textile revolution isn't about choosing one material over another - it's about creating a diverse, sustainable portfolio where recycled polyester and cotton each contribute their unique strengths to a greener future.
