Polyester fibers possess high strength and excellent abrasion resistance; however, their smooth surfaces and weak inter-fiber cohesion are the root causes of the pilling often seen in polyester fabrics. When the fabric undergoes friction, fiber ends on the yarn surface are pulled outward, creating fuzz. Due to the high breaking strength of polyester, these pulled-out fibers do not easily break off; instead, they tangle and clump together, forming visible pills that adhere firmly to the fabric surface.
Strategies to mitigate polyester pilling can be implemented at two stages: yarn production and fabric finishing. During spinning, the process can be optimized to reduce yarn hairiness; using profiled (non-circular) cross-section polyester staple fibers helps minimize fiber slippage, while increasing yarn twist enhances inter-fiber cohesion, thereby reducing fiber pull-out. In the fabric processing stage, singeing can be employed to burn off surface fuzz, or padding treatments with anti-pilling agents can be used to form a thin film on the fiber surface, reducing slippage. Blending with small amounts of other fibers is another option to alter frictional characteristics. However, it is important to note that anti-pilling treatments increase costs, and certain chemical finishes may affect the fabric's hand-feel; therefore, a balance between hand-feel, cost, and the desired anti-pilling grade must be struck based on product positioning. When sourcing fabrics for home textiles or apparel, it is essential to specify requirements regarding national anti-pilling grade standards and conduct preliminary sample testing.