Is Cotton Toxic? Mercerized, Combed & Other Cotton Types Explained

Is Cotton Really the Most Toxic and Least Sustainable Fabric?

Global cotton production reached 25.3 million metric tons in 2023, with major producers including India (24%), China (22%), and the United States (15%). Organic cotton now accounts for 14% of production, driven by rising demand in fast fashion and sportswear, while recycled cotton usage has climbed to 22%. Cotton boasts exceptional properties: an 8.5% moisture absorption rate (far exceeding polyester’s 0.4%), three times the breathability of polyester, a heat resistance threshold of 150°C, and natural antimicrobial efficacy of 72%. However, cotton cultivation consumes 16% of global pesticides and 4% of fertilizers, with 15,000 liters of water required to produce 1 kg of cotton. With genetically modified (GM) cotton now dominating 76% of production, ecological sustainability has become a critical industry focus.Many people now ask questions like “is cotton toxic?”, “why is cotton bad for you?”, or “what are the disadvantages of cotton compared with other fabrics?”. In this article we’ll look at how cotton is grown and processed, and 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 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, requiring no fiber extraction (polyester, nylon, acrylic).

Cotton plants are tropical crops with four main varieties:

- Asiatic

- African

- Upland cotton (originating in Central America; 90% of global production due to high yield and economic viability).

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

II. Cotton Processing and Challenges

Cotton requires a 6-month growth cycle. After machine harvesting, it undergoes:

1. Drying: Heat-treated to remove moisture.
2. Ginning: Separating seeds and debris.
3. Carding: Aligning fibers uniformly.
4. Spinning and Drawing: Twisting fibers into yarn through multiple passes.

Environmental Concerns

- Producing one  cotton T-shirts and golf polos consumes ~2,700 liters of water (10 days of human water use).

- Cotton occupies 2.5% of global farmland but uses 25% of agricultural pesticides, contaminating ecosystems and threatening worker health.

- GM cotton (80% of crops) boosts yield and pest resistance but raises sustainability debates.

Organic Cotton

- Prohibits GM seeds and synthetic pesticides.

- Reduces water use by 98% but yields 30% less than conventional cotton, requiring more land and labor.

III. Blended Fabrics: Pros and Cons

While cotton excels in breathability and comfort, its drawbacks (poor colorfastness, shrinkage, low elasticity) make blended fabrics predominant. Blends combine cotton’s softness with synthetic performance:

1. Poly-Cotton Blend

   - Strengthens dye retention and wrinkle resistance but reduces breathability. Often deceptively marketed as "pure cotton."

2. Washed Cotton

   - Pre-shrunk via high-temperature washing for smoother texture and color retention. Higher cost.

3. Lycra Cotton (Spandex Blend)

   - Adds stretch and durability for activewear. "Lycra" is a brand name for spandex ("iPhone" vs. "cellphone").

4. Mercerized Cotton

   - Treated with sodium hydroxide to enhance luster and absorbency, but weakens fiber structure.

5. Slub Cotton

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

6. Canvas Cotton

   - Dense, stiff weave ideal for durable bags.

7. Combed Cotton

   - Extra carding removes impurities for softer, stronger yarn.

8. Ice Cotton

   - Coated for a cooling, silky feel.

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 usually 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 its environmental disadvantages, not that the fabric will poison the wearer. Conventional cotton uses a lot of 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 cons 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 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 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 are 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 the 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 to 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.

Conclusion

Pure cotton garments are rare today, as blends address cotton’s limitations. For 100% cotton apparel, expect extra care (e.g., pre-shrinking). The industry’s future hinges on balancing cotton’s natural benefits with innovations in sustainability and blended technologies.

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.

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