Unwrapping Polyester: The Health Risk Lurking in Your Clothes

In the realm of modern textiles, polyester is ubiquitous. Found in everything from t-shirts to underwear, bedsheets to sportswear, it’s cheap, wrinkle-resistant, and easy to mass produce. But beneath its convenience lies a web of health concerns that are rarely discussed. Polyester, a synthetic fibre derived from petroleum, carries with it significant risks to both human health and the environment—especially when worn in direct contact with skin.

This article explores how polyester is made, what happens when you wear it, and why it may be time to rethink this dominant fabric.

What Is Polyester Made From?

Polyester is a category of polymers formed through the chemical reaction between ethylene glycol (a petroleum by-product) and dimethyl terephthalate. The process involves high heat and toxic catalysts, resulting in long-chain plastic fibres. These fibres are then spun into threads and woven or knitted into fabric.

From its origin, polyester is a plastic—one that’s chemically treated, dyed, and finished using a cocktail of stabilisers, dyes, flame retardants, and anti-pilling agents.

Health Concerns of Wearing Polyester

1. Skin Irritation and Allergies

Polyester does not breathe. When worn in warm or humid climates, it can trap sweat and heat close to the skin, creating a breeding ground for bacteria and fungi. This can lead to:

• Rashes

• Contact dermatitis

• Fungal infections in sensitive areas

A study in the American Journal of Contact Dermatitis highlighted synthetic fibres, including polyester, as a common irritant for individuals with sensitive skin or eczema.¹

2. Endocrine Disruption from Chemical Additives

Polyester garments often contain chemical finishes such as:

• Formaldehyde (for wrinkle resistance)

• Perfluorinated compounds (PFCs) (for stain and water repellency)

• Phthalates (from dyes and prints)

Many of these are known endocrine disruptors—substances that can interfere with hormone function. Repeated exposure to such chemicals, especially through skin contact or off-gassing, has been linked to hormonal imbalances, reproductive issues, and developmental problems in children.²

3. Microplastic Shedding

With every wash, polyester garments release microscopic plastic fibres—called microplastics—into water systems. These are too small to be filtered out and eventually enter our drinking water, food chain, and bodies.

A 2021 study published in Environmental Science & Technology estimated that the average person ingests over 5 grams of plastic per week—roughly the weight of a credit card.³

4. Respiratory Risks from VOCs

Some polyester items—especially those with finishes like waterproofing or antimicrobial coatings—emit volatile organic compounds (VOCs) such as toluene and benzene. These chemicals can cause dizziness, headaches, and long-term respiratory damage with prolonged exposure.

Indoor environments with high levels of synthetic fabrics (e.g., polyester carpets, curtains, furniture) can significantly increase VOC concentration.⁴

Occupational Hazards in Polyester Production

Textile workers involved in polyester manufacturing and dyeing are frequently exposed to hazardous substances. According to the World Health Organization (WHO), chronic exposure to solvent-based dyes and polyester resins has been linked to:

• Skin and eye irritation

• Lung inflammation

• Increased risk of certain cancers⁵

Additionally, dyeing polyester requires disperse dyes, which are not water-soluble and can remain embedded in the fabric, leaching out with sweat.

Polyester and Heat: A Dangerous Combo

Polyester has a low melting point (~250°C), which means it can melt onto the skin in the event of a fire. For this reason, many fire safety experts recommend avoiding polyester garments (especially undergarments) for children, factory workers, and motorcyclists.

Regulations and Gaps

While some countries have imposed limits on formaldehyde and heavy metals in textiles, there is no global regulatory consensus on the chemical safety of clothing. The EU’s REACH regulation and California’s Proposition 65 have improved transparency, but enforcement remains inconsistent. In India, textile chemical safety remains largely unregulated at the consumer level.

Healthier Alternatives

If you're looking to reduce exposure to harmful substances in your wardrobe, consider switching to:

• Cotton (GOTS-certified): Breathable, hypoallergenic, and biodegradable

• Linen (Flax): Moisture-wicking and naturally antimicrobial

• Hemp: UV-resistant, breathable, and strong

• Tencel (Lyocell): Made from wood pulp using non-toxic solvents

• Wool (organic): Naturally insulative and odour-resistant

Each of these fabrics can offer better moisture management, fewer chemical residues, and a lower environmental footprint.

Polyester is everywhere, and avoiding it completely may not be practical. But understanding its risks—especially when worn directly on the skin or used in intimate apparel—can help consumers make more informed choices. As awareness grows and regulation catches up, it’s time to elevate the conversation around what we wear, not just how it looks.

Your health begins with what touches your skin. Choose consciously.