Dow and its collaborators have developed innovative polyethylene (PE) architectures and recycling technologies to enhance sustainability and reduce emissions. A novel long-chain branching PE design improves industrial applications and supports lower-carbon production. An upcycling process, created with leading universities, converts PE into polypropylene (PP) with high efficiency, addressing plastic waste and reducing emissions. In partnership with Procter & Gamble, Dow has also advanced dissolution-based recycling for hard-to-recycle plastics, yielding near-virgin quality PE. These innovations support a circular economy and reflect Dow’s commitment to sustainable materials and environmental progress.
Scientists from Dow, alongside collaborators from leading universities and industries, have unveiled groundbreaking advancements in polyethylene (PE) architecture and recycling processes. These developments aim to reduce greenhouse gas emissions, enhance material circularity, and accelerate the transition to a sustainable future.
Novel Polyethylene Architecture with Long-Chain Branching
Dow researchers have developed a novel polyethylene architecture featuring long-chain branching, offering unprecedented flexibility in industrial applications while potentially reducing carbon emissions during large-scale PE production. The work, detailed in a Science publication, represents a milestone in polymer chemistry.
The innovation relies on a unique catalytic mechanism where two growing polymer chains on the same metal are coupled via a diene in a ladder-like process. This efficient system enables favorable kinetics and yields PE with improved processing properties, allowing its production across diverse reactor configurations.
“Dow has a bold vision to create materials and solutions that address global challenges such as climate change, resource scarcity, and plastic waste,” said Stephanie Kalil, Senior Global Business Director, Packaging & Specialty Plastics. “This game-changing innovation will enhance our industry-leading portfolio and sustainability efforts.”
Beyond improving industrial flexibility, the multi-functional PE could enable downgauging in packaging applications, reducing material usage and waste. Dave Parrillo, Vice President of R&D for Dow Packaging & Specialty Plastics, emphasized the technology’s role in “unlocking novel microstructures for lower carbon emissions and safer products across diverse sectors, including infrastructure, healthcare, and transportation.”
The research was led by Robert Froese and a team spanning Dow’s facilities in Midland, Michigan; Lake Jackson, Texas; and Terneuzen, The Netherlands.
Upcycling Polyethylene into Polypropylene
In collaboration with the University of Illinois Urbana-Champaign and UC Santa Barbara, Dow researchers have pioneered a process to transform polyethylene—commonly found in packaging and other applications—into polypropylene (PP), the second-most produced plastic globally. This upcycling innovation addresses the growing need to manage plastic waste while reducing greenhouse gas emissions.
The approach employs a sequence of catalytic reactions to break down PE into propylene molecules, the building block of PP, with a selectivity exceeding 95%. The process, proven in a continuous-flow reactor, is scalable and compatible with current industrial systems.
“Our analysis suggests that converting 20% of global PE waste via this method could reduce emissions equivalent to taking 3 million cars off the road,” noted Garrett Strong, a graduate researcher on the project.
This work complements other innovations in plastics recycling by prioritizing energy efficiency. Unlike batch processes requiring high pressure, the team’s flow reactor method minimizes energy use while maximizing output.
Advances in Recycling Technologies with Procter & Gamble
Dow and Procter & Gamble (P&G) have entered a joint development agreement to create a dissolution-based recycling technology aimed at recovering polyethylene from hard-to-recycle plastic waste. By combining their patented technologies, the partners aim to produce near-virgin quality recycled PE with a lower emissions footprint.
Dissolution uses solvents to selectively separate polymers and additives, targeting rigid, flexible, and multi-layered packaging waste. Dow’s Vice President of R&D, Dave Parrillo, stated, “We are committed to transforming plastic waste into high-quality resins that accelerate the circular economy.”
Both companies have ambitious sustainability goals. Dow aims to commercialize 3 million tonnes of circular and renewable materials by 2030, while P&G plans to design 100% of its consumer packaging to be recyclable or reusable by the same year.
The Path Toward a Circular Plastics Economy
These advances collectively address critical challenges in plastics manufacturing, waste management, and sustainability. From Dow’s novel PE architecture to the upcycling and dissolution technologies, the innovations demonstrate a unified commitment to reducing environmental impacts and creating a circular economy for plastics.
Jim Fitterling, Dow’s CEO, predicts that mechanical recycling will account for 15% of global PE demand by 2050, with chemical recycling, bio-based feedstocks, and low-carbon solutions fulfilling the remainder. As research continues, partnerships like those with universities and P&G will play an essential role in scaling these technologies for global impact.
