Cotton or Polyester Thread for Sewing Machine: A Comparison

Choosing the right thread is critical for garment wholesalers and manufacturers, as it directly impacts the durability, appearance, and efficiency of the production process. Using a good thread is essential for achieving optimal sewing results, as a smooth and durable thread helps prevent issues like fraying or breakage during sewing. Among the most widely used threads in the textile industry are cotton thread and polyester thread. Each has unique characteristics and benefits, making them suitable for different applications.

This blog will help you understand the key differences between cotton and polyester threads, giving you the information needed to make the best choice for your projects and operations.

What is Cotton Thread?

Definition and Properties

Cotton thread is made from natural fibers derived from the cotton plant. Cotton thread is especially well-suited for use with cotton fabric due to their shared natural properties and compatibility. Known for its soft texture and excellent sewability, it is a popular choice for certain types of sewing projects. Cotton thread ranges from mercerized (a process that enhances strength and sheen) to unmercerized forms, with variations catering to specific needs.

Common Uses in the Garment Industry

Cotton thread excels in applications where the natural look and feel of the thread complement the fabric. Areas where it’s often used include:

• Quilting, especially for piecing, as cotton thread is well-suited for creating strong, reliable seams when working with cotton fabrics

• Stitching with lightweight natural fabrics like cotton or linen

• Hand embroidery.

Cotton thread’s compatibility with natural fabrics, particularly cotton fabrics, ensures consistency in properties like washing, dyeing, and wear over time.

Pros and Cons of Using Cotton Thread

Pros:

• Soft texture: Offers an ideal finish for lightweight, soft fabrics.

• Natural composition: Biodegradable and eco-friendly.

• Low heat resistance: It can handle high ironing temperatures and withstand high temperatures during ironing and pressing.

• Easily dyed: Cotton thread can be easily dyed, allowing for a wide range of color options.

Cons:

• Low elasticity: Can break under high tension, especially in heavy-duty sewing.

• Weaker compared to synthetic options: Cotton threads wear out faster under continuous strain.

• Limited flexibility: Poor performance with stretchy or synthetic fabrics.

• Susceptible to fraying: Cotton thread may be more prone to fraying, especially after repeated washing or heavy use.

What is Polyester Thread?

Definition and Properties

Polyester thread is a synthetic product made from polyester fibers. As a synthetic thread, polyester is manufactured by twisting and stretching the fibers to enhance their high tensile strength, making it exceptionally durable for demanding sewing applications. It is known for its strength, elasticity, and resistance to shrinking, making it an optimal choice for industrial applications. Typically, polyester threads are available in multiple finishes, such as core-spun, trilobal, and textured, each serving specific purposes.

Common Uses in the Garment Industry

Polyester thread is widely used across various applications, such as:

• Heavy-duty industrial stitching

• Upholstery and heavy duty fabrics: Ideal for sewing durable materials like denim, canvas, and leather, making it suitable for upholstery, outdoor gear, and workwear.

• Boat covers: Perfect for outdoor and marine applications due to its strength and resistance to UV rays and moisture.

• Machine embroidery: Commonly used for decorative stitching and embroidery because of its strength, colorfastness, and variety of finishes.

• Stretch garments like activewear and swimwear

• High-speed or automated sewing machines.

Its versatility makes it a go-to option for large-scale, high-performance sewing demands.

Pros and Cons of Using Polyester Thread

Pros:

• Durability: Resists wear and tear, ensuring a longer lifespan.

• Highly durable: Polyester thread is highly durable, making it suitable for projects that require long-lasting seams.

• Less lint: Produces less lint compared to natural fiber threads, resulting in cleaner sewing and less machine maintenance.

• Elasticity: Performs well with stretchy and synthetic fabrics.

• Moisture resistance: Retains strength even in damp environments.

Cons:

• Shine may stand out: The synthetic sheen may look out of place on natural fabrics.

• May melt under high heat: Care is needed during ironing or pressing.

• Environmental concerns: Polyester is not biodegradable, raising sustainability issues.

Key Differences Between Cotton and Polyester Threads

Durability and Strength

Polyester thread outshines cotton thread in terms of tensile strength and durability. Thread weight plays a crucial role in determining overall strength—thicker threads, which have a lower weight number, are preferred for heavy-duty fabrics and projects that require extra durability. While cotton thread is best suited for lightweight, low-stress applications, polyester thread works seamlessly for heavy-duty and high-stress projects, including industrial sewing.

Cost Comparison

Polyester threads are generally more affordable than cotton threads, especially when calculating cost per unit for large-scale industrial use. This affordability makes polyester the more economical option for bulk production scenarios. All purpose thread, often a cotton-wrapped polyester, offers a cost-effective and versatile solution for many sewing projects, balancing affordability and performance.

Maintenance and Care

Cotton thread can withstand heat well, making it suitable for high-temperature ironing. Proper bobbin selection and careful thread winding are important for maintaining thread performance and ensuring smooth sewing results. However, it shrinks and loses strength over time with frequent washing. Polyester thread is maintenance-friendly. It doesn’t shrink, resists stains, and maintains its structure and color after multiple wash cycles.

Environmental Impact

Cotton thread, being biodegradable, is considered more sustainable than polyester, which is derived from non-renewable petroleum resources. Fabric and thread blends, such as cotton-polyester, can influence both the environmental impact and the performance characteristics of the final product. However, the production of cotton threads can have its environmental costs, such as water and pesticide usage. Some manufacturers now focus on organic and sustainably sourced cotton to mitigate this. Polyester thread, on the other hand, often contributes to microplastic pollution due to its synthetic nature.

Which Thread Should You Choose?

Factors to Consider

When deciding between cotton and polyester threads, garment wholesalers and manufacturers should evaluate the following factors:

• Fabric type: Natural fabrics pair well with cotton thread, while synthetic and elastic fabrics perform better with polyester thread. It is important to select a good match between the thread and the fabric by considering fiber content, color, and weight to ensure compatibility and optimal sewing results.

• Project requirements: For lightweight, soft, or decorative projects, cotton thread is ideal. However, heavy-duty or high-volume production benefits greatly from polyester’s durability and elasticity. Using a quality thread ensures better durability and a professional finish.

• Budget: Polyester is typically more cost-effective for large-scale manufacturing needs.

• Sustainability goals: Those aiming to reduce their carbon footprint might favor organic cotton thread despite its higher cost.

Recommendations Based on Garment Types

1. Casual wear: Use polyester thread for its versatility and ability to handle various materials. Polyester thread is commonly used to sew a wide variety of clothes due to its strength and adaptability.

2. Quilts and lightweight natural fabrics: Cotton thread enhances the natural aesthetic and complements these materials.

3. Activewear: Polyester thread’s elasticity and durability make it the clear choice.

4. Industrial applications: Polyester thread offers the strength needed for heavy-duty operations.

Tips for Wholesalers and Manufacturers

1. Partner with reliable thread suppliers to ensure consistent quality across projects. Always source good quality thread to guarantee durability and smooth sewing performance.

2. Stock both cotton and polyester threads to cater to varied needs and preferences. It is also recommended to stock a variety of thread types, as different materials and properties are best suited for specific fabrics and sewing techniques.

3. Test threads in your sewing machines to ensure compatibility with equipment and fabrics.

Choosing the Right Thread for Success

Understanding the differences between cotton and polyester threads can help garment wholesalers and manufacturers improve product quality, operational efficiency, and overall customer satisfaction. Understanding the unique properties of both cotton and polyester threads—such as their strength, durability, and suitability for different fabric types—is key to making the best choice for any sewing project. Cotton thread’s natural appeal and eco-friendliness make it perfect for niche or delicate applications, while polyester thread excels in durability, strength, and cost-effectiveness for bulk production.

Choosing the right thread depends on the specific demands of your fabric, project, and business. Share your experiences with cotton and polyester threads in the comments below, or reach out to us with any questions. Together, we can thread the needle toward a better sewing future.