In 2023, Virginia Tech researchers turned plastic bags and food containers into soap-making surfactants; the products could be worth about $3,550 a ton in a lab-scale process

Most plastic bags, food containers, and milk jugs you see around you eventually end up in landfills. However, researchers from Virginia Tech have found a creative way to turn this everyday waste into something useful: soap. According to the study, ‘Chemical upcycling of polyethylene, polypropylene, and mixtures to high-value surfactants,’ published in the journal Science in August 2023, common plastics could be broken down and rebuilt into surfactants, the compounds that make soap and detergent work. The economic potential of this process makes sense as well since polyethylene sells at $1,150 per metric ton, while the surfactants it can become are worth up to $3,550 a ton.

A fireplace evening sparked the idea

The breakthrough didn’t start in a lab; it began by a fireplace when Guoliang "Greg" Liu, an associate professor of chemistry at Virginia Tech, saw smoke rising from burning wood one winter night. He started thinking about how wood is made of long chains of natural polymers, and how plastic is built the same way, except that it is made of carbon-based molecules instead. That thought led him somewhere unexpected. Polyethylene is one of the most popular plastics on the planet and happens to have a chemical structure very similar to that of fatty acids, which are used to build soap. Both have long chains of carbon molecules, but the only difference lies in the presence of an additional molecular structure at one end of the fatty acid molecule. Liu began to wonder if there was a way to bridge that gap.


Breaking down plastic, step by step

Turning that idea into a working method took years of trial and error. Liu worked with his two PhD students, Zhen Xu and Eric Munyaneza, to develop a reactor that heats plastic from the bottom while keeping the upper side cool. This technique, known as temperature-gradient thermolysis, breaks long polyethylene chains into shorter ones, stopping the breakdown at the wax stage before the chains degrade all the way into gaseous molecules. The researchers then oxidized this wax through the use of a manganese oxide-based catalyst to produce fatty acids, which are molecules similar to the ones used to make soap. A few more chemical steps convert those fatty acids into surfactants, which can be shaped into bars of soap or used in liquid detergent. The process is not limited to milk jugs and grocery bags. In fact, according to the research, this technology can also work with polypropylene, which is also a common plastic that can be found in various everyday products such as yogurt containers and bottle caps. These two types of plastics do not have to be separated prior to being processed in the reactor.

Why the price gap matters

Recycling would be successful if it makes economic sense, and this is exactly where this technology succeeds. While raw polyethylene waste costs $1,150 per metric ton, the surfactant obtained from it can fetch up to $3,550 per metric ton, which is more than thrice its initial price. That price gap is one reason researchers see commercial potential in the technology, because recycling the plastic could be more economical than discarding it.

Small beginnings, big potential

For now, this remains a laboratory-scale breakthrough. As Liu stated, his team can create only about half a gram of surfactant per attempt, roughly the weight of one pumpkin seed. The challenge will be scaling up the process so it can handle tons of plastic waste a day. Such a challenge is important considering how vast the plastic problem is. According to the study, ‘Production, use, and fate of all plastics ever made,’ published by Roland Geyer and colleagues in the journal Science Advances, about 8,300 million metric tons of virgin plastic had been manufactured at that time. Of the 6,300 million metric tons of plastic waste generated until 2015, only 9 percent was ever recycled, whereas 79 percent ended up in landfills or in the environment. Against those numbers, a method that can profitably convert plastic waste into something useful looks like a meaningful step forward, even if it starts small.

Liu's lab didn’t stop at soap. A follow-up study titled ‘Chain-length-controllable upcycling of polyolefins to sulfate detergents’ published in Nature Sustainability in 2024 further developed the original technique to produce sulfate detergents with improved properties for foam production and cleaning performance, while giving researchers more control over molecule size. In the study, the team showed that a chain-length-selective catalyst could tune the alkyl sulfate products they made from polyolefins, letting them shift from shorter to longer surfactant chains without rebuilding the whole process. They report that the resulting detergents gave better foaming and cleaning performance when chain length was optimized, and that the method worked on both polyethylene and polypropylene feedstocks.

What this could mean for you

It doesn’t mean that your local grocery store will be selling soap made from plastic any time soon. However, the process is scientifically sound and has been peer-reviewed, even if the commercial production and safety testing are yet to take place. For readers interested in sustainability but aware of how slowly change happens, this research offers a useful reminder. Solutions to the plastic crisis might not always look like reducing consumption or banning products; sometimes they look like researchers finding a clever way to give old plastic a second but useful life.