Is Cotton Really the Most Toxic and Least Sustainable Fabric?

Global cotton production reached about 25.3 million metric tons in 2023, with major producers including India, China, and the United States. Many people now ask questions like “is cotton toxic?” “is cotton fabric toxic?” “is mercerized cotton toxic?” “is combed cotton toxic?” or “what are the disadvantages of cotton?”

Here’s the quick answer upfront:

• Cotton fiber itself is not toxic in normal wear.

• Most “cotton toxicity” concerns come from farming chemicals, dyes, and finishing agents—or from whether a specific process (like mercerized cotton) is properly neutralized and rinsed.

• For sensitive-skin programs, the safest path is tested and documented cotton (and controlled finishing), not marketing claims.

Industry snapshot (often-cited estimates): Organic cotton is frequently reported at around ~14% of global cotton output, recycled cotton usage is often cited around ~22% in apparel supply chains, and GM cotton is commonly reported at ~75–80% of production (figures vary by source and year).

In this article, we’ll look at how cotton is grown and processed, then review different cotton fabrics such as mercerized, combed, washed, and recycled cotton so you can understand which options are actually safe—and where the real problems can lie.

Today, we’ll explore cotton in three modules:

1. Fiber types and cotton varieties

2. Cotton processing and challenges

3. Blended fabrics and their pros/cons

Everything You Need to Know About Cotton

I. Fiber Types and Cotton Varieties

Cotton has been cultivated for over 7,000 years, making it one of humanity’s oldest natural fibers alongside wool and linen. Modern textiles now include synthetic fibers like polyester, acetate, acrylic, and nylon. Fibers broadly fall into two categories: natural and synthetic.

Natural fibers are derived from plants or animals:

• Protein fibers: Wool, Silk

• Cellulose fibers: Cotton, Linen

Synthetic fibers are chemically produced and classified as:

• Regenerated: Made from natural materials (bamboo, soy, wood pulp) processed into fibers (viscose, lyocell).

• Inorganic: Rare in apparel (metal, ceramic, carbon fibers).

• Synthetic polymers: Made from petrochemicals (polyester, nylon, acrylic).

Cotton plants are tropical crops with four main varieties:

• Asiatic

• African

• Upland cotton (widely used in global supply due to yield and cost efficiency)

• Sea Island cotton (extra-long staple fibers for premium textiles)

Why cotton still matters (performance snapshot): Cotton is often reported with a moisture regain around ~8.5% (polyester is commonly cited near ~0.4%), and it’s frequently described as offering much higher breathability in comparable fabric constructions (often summarized as ~3× in practical comparisons). Cotton is also commonly referenced with heat tolerance around ~150°C for typical finishing/ironing contexts. In lab-based discussions, cotton may show measurable natural antimicrobial behavior (figures such as ~72% are sometimes cited depending on test method and conditions).

II. Cotton Processing and Challenges

Cotton requires a multi-month growth cycle. After harvesting, it typically undergoes:

• Drying: Heat-treated to remove moisture

• Ginning: Separating seeds and debris

• Carding: Aligning fibers uniformly

• Spinning and Drawing: Twisting fibers into yarn through multiple passes

Environmental Concerns (why people say “why is cotton bad for you?”)

When people search “why is cotton bad for you?” they usually mean its environmental disadvantages—not that cotton will poison the wearer. Conventional cotton can involve significant water use and agricultural inputs, which can impact soil, waterways, ecosystems, and worker exposure depending on region and practices.

Environmental punchline (widely quoted): Producing 1 kg of cotton is often cited as requiring up to ~15,000 liters of water in water-stressed systems, and a single cotton T-shirt is frequently estimated around ~2,700 liters across its supply chain. Cotton is also commonly described as occupying a small share of farmland (often cited near ~2.5%) while accounting for a disproportionately high share of pesticide use (figures vary—often cited in the ~16–25% range depending on dataset and year).

GM cotton and sustainability debates

GM cotton is widely used to improve yield and pest resistance in many regions, but it also sits at the center of sustainability discussions—how inputs are managed, how land is used, and what long-term ecological tradeoffs look like.

Organic cotton (what it changes)

Organic cotton typically:

• Prohibits GM seeds and many synthetic pesticides

• Reduces certain upstream chemical risks, depending on farm practices and certification scope

• Involves yield/cost tradeoffs in many regions

For end consumers, organic cotton is primarily a risk-reduction and sustainability positioning choice. For brands, it can also be a traceability and compliance story—when the documentation is solid.

III. Blended Fabrics: Pros and Cons

Cotton is loved for comfort and breathability, but its drawbacks—poor wrinkle resistance, shrinkage risk, slow drying, and low elasticity—are why blends are common in modern apparel.

Below are common cotton-related fabric types and what they really mean:

1. Poly-Cotton Blend

• Strengthens wrinkle resistance and often improves care performance, but can reduce “pure cotton” breathability/handfeel depending on ratio and structure.

• Sometimes marketed loosely as “cotton” in consumer language—buyers should verify fiber content.

2. Washed Cotton

• Pre-washed at the mill to soften texture and reduce shrink.

• Performance depends on controlled wash chemistry and thorough rinsing.

3. Lycra Cotton (Spandex Blend)

• Adds stretch and durability for activewear and fitted silhouettes.

• “Lycra” is a brand name for spandex (iPhone vs cellphone).

4. Mercerized Cotton

• Treated to enhance luster and dye uptake, producing a smoother, more premium look.

• Key safety point: it must be properly neutralized and rinsed after treatment.

5. Slub Cotton

• Woven with uneven yarns for a textured, node-like surface.

• Search terms like “slub cotton is good or bad” are usually about texture and durability, not toxicity.

6. Canvas Cotton

• Dense, stiff weave ideal for durability (bags, heavy-duty use).

7. Combed Cotton

• Extra mechanical refining removes short fibers and impurities for smoother, stronger yarn.

8. “Ice Cotton” / Cooling Cotton

• Usually achieved via yarn structure, finishing, or blends—brands should verify what the “cooling” claim is based on.

IV. FAQ – Is Different Cotton Toxic or Safe?

Is cotton toxic?

In normal use, cotton fiber itself is not toxic. Most concerns about whether cotton is toxic or whether cotton fabric is toxic come from farming chemicals and some finishing agents—not from the cellulose fiber. Once the fabric has been properly washed and finished, residue levels are typically very low and regulated in most export markets. People with very sensitive skin may react to certain dyes or softeners, so choosing certified, low-chemical cotton is safer.

Why is cotton bad for you? (Disadvantages of cotton)

When people talk about the “bad things about cotton,” they usually mean environmental disadvantages, not that the fabric will poison the wearer. Conventional cotton can require significant water and, in some regions, heavy pesticide and fertilizer inputs; this can harm soil, rivers, and farm workers. Cotton garments can also shrink, wrinkle, and dry slowly compared with synthetics. For most wearers, these are practical disadvantages of cotton rather than direct health risks.

Is mercerized cotton toxic?

Mercerized cotton is regular cotton that has been treated with sodium hydroxide and then thoroughly washed and neutralized. When the process is controlled and the fabric is properly rinsed, no caustic soda remains on the fiber, so mercerized cotton is not considered toxic for consumers. The main impact is in the wet-processing stage at the mill, which should have good chemical handling and wastewater treatment.

Is mercerized cotton safe for skin?

For most wearers, yes—mercerized cotton is safe for skin when produced by compliant mills and properly neutralized. For sensitive-skin programs, brands should rely on testing and documentation rather than assumptions.

Is combed cotton toxic?

Combed cotton simply means the short fibers and impurities have been mechanically removed to make a smoother, stronger yarn. No extra chemicals are needed beyond normal spinning finishes, so combed cotton is not toxic by itself. Its real impact depends on how the original cotton was grown and what dyes or finishes are later added to the fabric.

Is washed cotton toxic?

“Washed cotton” usually refers to cotton fabric that has been pre-washed at the mill to soften it and reduce shrinkage. Standard industrial detergents and enzymes may be used and then rinsed away. As long as the fabric passes basic safety and color-fastness tests, washed cotton is not considered toxic for everyday wear.

Is recycled cotton toxic?

Recycled cotton is made from cutting waste or post-consumer garments that are shredded back into fiber and spun again. The recycling process itself is mostly mechanical, but original garments may have contained different dyes and finishes. This means recycled cotton is not automatically more toxic, but brands should work with spinners who test for restricted substances and control color sorting.

Is 100% cotton non toxic and is cotton durable?

For most people, 100% cotton from reputable mills is non-toxic and skin-friendly, especially if it is certified (for example OEKO-TEX or similar standards). Cotton fibers have good strength in dry conditions, so cotton clothing can be very durable if the fabric weight, yarn quality, and construction are chosen well. The main weaknesses are abrasion when wet, shrinking without pre-shrinking, and slower drying compared with synthetics.

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Conclusion

Cotton is not inherently “toxic.” The real risks—when they exist—are typically tied to process control: chemical handling at the mill, dyes and finishes, neutralization and rinsing, and whether compliance testing is done. That’s also why modern apparel often uses blends to balance cotton’s comfort with performance and easy care.

If you are sourcing custom golf or fishing apparel, Qiandao Apparel Factory can help you choose the right cotton or cotton-blend fabric for your next collection—from classic piqué golf polos to lightweight fishing shirts—based on comfort targets, wash durability, and export-market compliance.