<p>This study investigates the influence of spinning process parameters on microfiber release from polyester fabrics, identifying yarn hairiness as the dominant controlling factor. Experimental results demonstrate an extremely high correlation (<i>R</i>² = 0.997) between 3&#xa0;mm hairiness and microfiber release, confirming protruding fibers as the primary shedding source. Among the parameters examined, spinning method exhibits greater influence than twist factor, with Siro compact spinning consistently delivering optimal performance by achieving minimal hairiness and microfiber release while maintaining high breaking strength. The optimal combination was determined as Siro compact spinning with a twist factor of 400. The research establishes that spinning method's effect on microfiber release is primarily indirect, mediated through its determination of yarn hairiness. These findings provide a scientific basis for source reduction of microplastic pollution in textiles, demonstrating that proper selection of spinning technologies and process parameters can significantly reduce microfiber shedding at the manufacturing stage. The study offers practical solutions for developing more sustainable textiles and advancing green manufacturing practices in the textile industry, contributing to environmental protection and circular economy objectives.</p>