The production of poly(butylene terephthalate) (PBT) struggles with the formation of substantial amounts of tetrahydrofuran (THF). When PBT is synthesized from terephthalic acid (TPA) instead of dimethyl terephthalate (DMT), even more THF is formed, mainly during the first stage of the melt polymerization process. Although a lot of literature reports on the existence of this side reaction in both processes, to the best of our knowledge, a comparison, which reveals the importance of the acidity and insolubility of TPA on the THF formation, was never described. Finally, an interesting study was performed on the THF formation during the synthesis of PBT from mixtures of DMT and TPA as well as from the completely soluble monomethyl terephthalate (MMT). (C) 2009 Wiley Periodicals, Inc. J Appl Polym Sci 114: 2427-2434, 2009