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All You Need to Know About the Polyester Staple Fiber

Table Of Content

If you are like most end-users, your knowledge goes as far as understanding it as a synthetic fiber. But did you know that Polyester as a fabric is complex and comes in various types?

Chemical fiber companies manufacture Polyester from petroleum. They use a chemical called Dimethyl Terephthalate in a polymerization process.

We have three main categories;

i. PCDT Polyester 

A less popular form of polyester. It’s like PET but with a different structure. Additionally, it is more elastic.

ii. Plant-based 

uses plant-based sources of ethylene such as sugarcane to create. The production process is still the same though.

iii. PET 

This is the most common form of polyester fiber industries produce. They combine petroleum ethylene (MEG) with dimethyl terephthalate (PTA) to make PET. The end product comes in four variants:

o Filament

o Staple

o Fiberfill

o Tow

To create the PET types, the company will cut or react the tow with chemicals to make one or all four variants.

The Polyester Staple fiber is a small constituent. In this article, we seek to shed light on this type of polyester fiber to help you have an understanding when you buy.

What is Polyester Staple Fiber?

As seen earlier, it is one form of PET polyester.

How Do They Make it?

After processing, PET is usually in a bundle of filaments called tow. They then cut the long filaments into short fixed lengths of between 32 to 64mm to make staple fiber. These lengths are almost the same as cotton fiber. Thus staple fiber is the best option for blending with other fibers.

Staple fiber created from raw materials MEG and PTA is what the industry refers to as virgin PSF. Those from PET bottle flakes are the Recycled PSF.

Most industries are embracing the production of recycled PSF. These have a less environmental impact because they use PET bottle flakes to make. This is their way to go green and help clean up the environment.

Types Existing in the Market

There are two types of staple fiber.

When spinning liquid polymer, the size of holes on the spinneret will make it into the hollow or solid fiber.

i. Hollow 

There is more space in the fiber giving a fluffy and light appearance.

ii. Solid (microfiber) 

the fibers have tiny diameters with no space between. These look thinner and finer.


The manufacturing company then uses chemicals to treat the two types of fiber. The treatment gives them various properties. These are like being fire resistant, non-static, non-shrinking, anti-fungal, conjugated, siliconized, and non-siliconized.

For conjugated the treatment works on the bonding to increase stability and elasticity.

Siliconization is the coating of fiber with silicon oil to give it an alluring soft feel. Spraying anti-static additive will reduce static electricity.

As you may notice on our website, PSF products come with names like HCS, HCNS, etc.

We combine these properties to produce staple fiber options available in the market.

These include:

  • Hollow conjugated siliconized fiber (HCS)
  • Hollow conjugated non-siliconized fiber (HCNS)
  • Flame retardant fiber
  • Solid fiber

Consumer Application and Uses

Polyester is the artificial twin of cotton. Essentially, it can replace all apparel with cotton fabric. That’s why the consumer world acknowledges it as the cheaper alternative to cotton.

We use it in many contexts such as apparel, homeware, and industries to make bottles, LCDs.

The fiber makes yarn for weaving fabrics.

In-home use for making furnishing products like carpets, sheets, curtains. As filler for sofas, pillows, stuffed toys, mattresses, quilts, padding, etc.

When it comes to PSF, texture affects use. For filling pillows, padding clothes, sofas hollow is the best option. Microfiber is ideal for making clothes, sheets because it’s compact.

Benefits You Get Using PSF?

It is resistant to environmental conditions making it useful for the outdoor.

The fiber is strong yet feathery perfect for upholstery.

It is cheap because the cost of production is lower than that of producing natural fibers.

It is easy to access. Chemical industries produce it in large quantities.

People dealing in staple fiber have a big target market. Its uses are many across various industries.

Easy to blend with other natural fibers like cotton when making fabrics. The elasticity helps reduce wrinkling and increases the durability of the garment.

Recycled staple fiber is sustainable and green.

In Conclusion

The world’s natural resource reserve is decreasing fast. There is a need for sustainable alternatives. Polyester staple fiber offers that solution. There was concern over the environmental challenges of using synthetic fiber. But, recycled PSF has gone a long way in making this option more favorable by the market. That means the global market demands will keep rising.

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