Expanding the plastics life cycle

Plastics make modern life possible.

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It’s a mistake to let biases against fossil fuels overshadow the absolute necessity for many plastic products. Plastic products help defend against disease, preserve food, and are used in medical equipment that saves lives.

As described in our Global Outlook, prosperity and population are expected to grow around the world between now and 2050. Plastics will be instrumental in supporting many of the United Nations Sustainable Development Goals, including good health, food preservation, and clean drinking water.

As living standards increase, plastics allow society to do more with less material and often with a smaller environmental footprint than alternatives.

Polyethylene (PE), for example, is the most commonly used polymer in packaging around the world. It has some important advantages over alternative materials (i.e., paper, glass, metal) – as shown in two recent peer-reviewed studies we commissioned.1 On a life-cycle basis, the total GHG emissions of PE are on average about half of those associated with the combined mix of alternative materials studied. PE packaging also uses four to five times less material than the alternatives studied.

Our approach

To meet society’s evolving needs, our efforts are focused both on enabling the societal benefits plastics provide and helping address the global issue of plastic waste. Our approach includes:

  • Leveraging our advanced recycling capacity to help further broaden the range of plastics that can be recycled;
  • Developing plastic solutions that enable our customers to make products that use less plastic; and
  • Developing plastic solutions that enable our customers to use more recycled plastics.

 

In transportation, plastics enable lighter vehicles, driving a 6% to 8% fuel efficiency gain for every 10% reduction in weight.2 The electric vehicle industry also relies on plastics to produce lightweight cars to extend battery range.

In agriculture, the plastic films made from our polymers support farming around the world by enabling:

  • Durable solutions for greenhouses that help farmers grow their crops all year long.
  • Long-lasting mulch solutions that use less material and help increase crop production rates.
  • Tough, puncture-resistant films for grain silos to reduce loss and spoilage.

Plastics are increasingly society’s material of choice due to their functional benefits and have overall lower life cycle greenhouse gas emissions compared to alternative materials in most applications.

Even lower-demand scenarios like the International Energy Agency’s Net Zero by 2050 (IEA NZE) project growth in plastics.

Supporting a more circular economy for plastics with advanced recycling

Mismanaged plastic waste is a global problem. We believe that a more circular economy for plastics is an important part of the solution.

Around the world, only about 9% of all plastics are recycled.3 Even in areas with better waste and recycling infrastructure, like the European Union, less than 27% of plastic waste is recycled4 once it leaves consumers’ hands. The rest is burned for energy, goes to landfills, or is discarded to the environment.

There are better uses for these materials.

We are helping to address the plastic waste challenge through advanced recycling (sometimes called chemical recycling) – giving plastic waste another life as new products that people need. Many products are difficult to recycle through mechanical recycling – the traditional method of grinding and melting plastic waste. But when both are used, mechanical recycling and advanced recycling can enable more types of plastic waste to be recycled.

With advanced recycling, plastic waste is broken down at the molecular level. This allows even complex blends of plastics to be turned back into usable raw materials. These are identical to the raw materials produced during the processing of fossil-based feedstocks and can be used to make a wide range of valuable products, including fuels, lubricants, and high-performance chemicals and plastics.

ExxonMobil’s technology for advanced recycling is not burning waste, which would consume the molecules and make it impossible to make new products out of them. Instead, we use a technology called “pyrolysis” to convert about 90% of the processed plastic waste into usable raw materials – a highly efficient process. 

 

For every ton of plastic waste processed through advanced recycling, society reduces the need to process ~1 ton of fossil-derived feedstocks.5

Waste plastic process
*ISCC PLUS mass balance approach using the “determined by mass” option with “certified free attribution” applied.
Certified-circular plastics do not represent specific amounts of GHG emissions or recycled content.

We sell certified-circular plastics corresponding to the amount of plastic waste we transform back into usable raw materials.6 We do this using a mass balance approach that has been used in other industries for many years. For every ton of certified-circular plastics sold, more than a ton of plastic waste avoids other end-of-life dispositions like landfill or incineration.

What is mass balance? In short, it is an accounting process that can be used in complex value chains like ours in which one input (e.g., plastic waste) is mixed with other inputs in a way that the different inputs cannot be physically traced throughout the system. This widely used approach helps our customers match the volume of their certified-circular plastic purchase to a corresponding amount of plastic waste that we transformed into usable raw materials through advanced recycling.

Similar concepts are used in other sectors to help customers and society keep track of their impact. For example, if you buy “renewable energy” from your electricity provider, you’re paying for that energy to be generated and added to the grid, but the electricity that reaches your house might come from a mix of sources.

Our advanced recycling facilities and process are certified via an independent, third-party certification system called International Sustainability and Carbon Certification (ISCC) PLUS. ISCC is an association of more than 300 members, including research institutes and NGOs.

The certificate we provide our customers (called an “ISCC PLUS Sustainability Declaration”) is not a claim that our certified-circular plastics contain specific amounts of “recycled content” or carry GHG benefits. Rather, it represents an assurance that we followed a rigorous mass balance attribution system that is certified by a third-party. This enables us to be transparent about our products, helping our customers, and their customers, progress and communicate circularity goals.

Baytown facility
Advanced recycling in Baytown, Texas.

Scaling up capacity to meet growing demand

There is rising demand from consumers and customers for circularity, far more than mechanical recycling can provide. Purchasing certified-circular plastics can enable our customers to achieve circularity goals, such as:

  • Unlocking the value of plastic waste by converting it into useful raw materials;
  • Monetizing the value of plastic waste to drive better collection and sorting;
  • Contributing to the growth of the recycling sector; and 
  • Accelerating plastic recycling rates.

Customers so far include Berry Global (now part of Amcor plc), Peel Plastics, Thanh Phu and Scientex, all supporting a more circular economy for food packaging.

Our third advanced recycling unit at our complex in Baytown, Texas, is now operational, a milestone that demonstrates our focus on addressing plastic waste and fostering a more circular economy.

With this addition, Baytown has the capacity to process up to ~250 million pounds of plastic waste annually. That means more plastics are diverted from landfills and transformed into raw materials for products people use every day.

As of January 2026, our Baytown site has processed more than 150 million pounds of end-of-life plastic – with more to come as we collaborate to get more plastic collected, sorted, and ready to process.

Increasing recycling rates through collaboration and innovation

Like most complex environmental challenges, broad collaboration is needed to address the issue of mismanaged waste. This includes rational and constructive policy and investment in waste-management infrastructure. Through organizations such as the Alliance to End Plastic Waste, we collaborate across the value chain to increase plastic waste collection and sorting to help support a more circular economy for plastics.

As a founding member of the Houston Recycling Collaboration (HRC), ExxonMobil is working with others in industry and government to increase access to plastic recycling in the Houston area. HRC was a leader in launching the Bag It & Bring It program. The initiative encourages community participation by accepting a wide range of plastics – including films and flexibles typically excluded from curbside recycling and destined for landfills. HRC has launched nine all-plastic drop-off locations in Houston, with nearly 2 million pounds collected so far. 

spotlight

Glassell School of Art's Again: The Future of Plastics project

Glassell School of Art students.

The Houston Recycling Collaboration (HRC) worked with the Glassell School of Art at the Museum of Fine Art's on Again: The Future of Plastics, a 14-week course engaging high school students in circular-economy principles. Throughout the semester, students collected plastic waste from Buffalo Bayou and challenged themselves to rethink how plastic is used, collected, and valued after use. Using recycled plastics, they designed and constructed mobile workstations for Hermann Park Conservancy – demonstrating how recycled plastics can be transformed to meet a community need.

Responsible manufacturing: the right products the right way

In our ExxonMobil Signature Polymers portfolio, we offer plastic film solutions designed with features intended to support recyclability. Actual recyclability depends on factors such as local collection, sortation, and recycling infrastructure, as well as the condition and configuration of the package after use.

Our VistamaxxTM performance polymers make recycling easier by making polyethylene and polypropylene more compatible, which allows them to “mix in the melt” and removes the need for mechanical recyclers to separate these materials for processing.

Collaboration can lead to even better results – and sometimes, simpler is better. For example, frozen food packaging usually needs several layers of different plastics, which makes mechanical recycling difficult. ExxonMobil collaborated with Tobe Packaging Industries Pte Ltd and Aegis Packaging to create a solution using ExceedTM Stiff polymers. The result is a simpler, single‑material package that offers comparable oxygen‑barrier performance while being easier for mechanical recyclers to process.

In other cases, we’re studying potential solutions to enable customers to use our polymers to do more with less – creating lighter or thinner products (i.e., “downgauging”). Examples include:

Our efforts are further supported by our systems to responsibly manage plastics manufacturing, including the global standards we have set across all of our resin-handling operations. These standards are more stringent than the laws and regulations related to plastic pellet loss in many of the places we operate, and we collaborate with industry through Operation Clean Sweep Blue in the U.S. to share best practices.10

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    Metrics and data

    FOOTNOTES:

    1. Polyethylene Packaging and Alternative Materials in the United States: A Life Cycle Assessment, February 2025, prepared by Trayak Inc. and published in the Science of the Total Environment 961 (2025) 178359. Life Cycle Assessment of Polyethylene Packaging and Alternatives on the European Market, June 2025, prepared by the University of Applied Sciences Vienna and Circular Analytics TK GmbH and published in Cleaner Environmental Systems 17 (2025) 100270. Both studies were conducted in collaboration with Michigan State University’s School of Packaging.
    2. U.S. Department of Energy statements at https://www.energy.gov/eere/vehicles/lightweight-materials-cars-and-trucks
    3.  Based on OECD Global Plastics Outlook: https://www.oecd.org/content/dam/oecd/en/publications/reports/2022/02/global-plastics-outlook_a653d1c9/de747aef-en.pdf
    4. See “Plastics Europe: The Circular Economy for Plastics: A European Analysis 2024” available at https://plasticseurope.org/knowledge-hub/the-circular-economy-for-plastics-a-european-analysis-2024/
    5. On a global, macroeconomic basis, assuming constant demand.
    6. Certified-circular plastics are virgin-quality plastics that are accompanied by a certificate that matches the mass of virgin quality plastics that we sell to a corresponding amount of plastic waste that we transformed back into usable raw materials through advanced recycling. Certified-circular plastics do not represent specific amounts of GHG emissions or recycled content.
    7. Compared to 80 µm reference material. For more information see: “Downgauged collation shrink film solutions” available at https://www.exxonmobilchemical.com/-/media/media-assets/media-library-assets/apr/kabra_collation_shrink_factsheet_en.pdf
    8.  "Thinner" refers to the thickness of heavy-duty sacks reduced to 120 microns from 140 micros (which is normally used in China). See “Video: Downgauged heavy-duty sacks incorporating 30% post-consumer recycled PE content maintain performance” available at https://www.exxonmobilchemical.com/en/resources/library/library-detail/103984/downgauged_heavy_duty_sacks_video_en
    9.  See “Video: Bonduelle creates high-performance, downgauged, recyclable*, non-laminated freezer film with brand appeal. A collaboration between ExxonMobil, Bonduelle and Constantia.” available at https://www.exxonmobilchemical.com/en/resources/library/library-detail/111438/bonduelle_case_study_landscape_v3 (*Recyclable in communities with programs and facilities in place that collect and recycle plastic film)
    10. Pellet loss refers to the unintended release of plastic resin into the environment during manufacturing, transportation, handling, or processing.