U.S. Plastic Production Calculator
Production Breakdown by State
The United States produces over 50 million tons of plastic every year. That’s more than any other country except China. But not all states contribute equally. One state stands out-not because of flashy factories or big brand names, but because of sheer volume, infrastructure, and decades of industrial focus. That state is Texas.
Texas Leads in Plastic Production by a Wide Margin
Texas accounts for nearly 30% of all plastic resin production in the U.S. In 2025, it manufactured over 14.5 million tons of plastic resins like polyethylene and polypropylene. That’s more than the next three states combined. The Gulf Coast region, especially around the Houston Ship Channel, is packed with petrochemical plants that turn natural gas and crude oil into the building blocks of plastic.
Why Texas? It’s not luck. The state has cheap natural gas from the Permian Basin, deepwater ports for exporting, and over 70 years of investment in chemical infrastructure. Companies like Dow, LyondellBasell, and Shell have built massive complexes here because the cost to produce plastic here is lower than anywhere else in North America.
How Plastic Production Works in Texas
Plastic doesn’t just appear out of thin air. It starts with ethane, a component of natural gas. Ethane is stripped from the gas stream and sent to crackers-huge industrial units that break the molecules apart using heat. The result? Ethylene, the raw material for polyethylene, the most common plastic in the world.
From there, ethylene moves to polymerization units where it becomes pellets. These pellets are shipped to manufacturers across the country to make bottles, bags, packaging, car parts, and toys. Texas doesn’t just make the pellets-it also makes the additives, solvents, and catalysts needed to turn them into finished products.
One facility in Port Arthur, operated by Shell, can produce 1.6 million tons of ethylene per year. That’s enough to make over 100 billion plastic bottles annually. And it’s just one of dozens of similar plants along the Gulf Coast.
Other Major Plastic-Producing States
Texas isn’t alone, but it’s far ahead. Here’s how the rest stack up:
- Louisiana: Produces about 4.2 million tons per year. Home to major plants by BASF and Formosa Plastics. The chemical corridor between Baton Rouge and New Orleans is dense with facilities.
- Pennsylvania: Around 3.1 million tons. Benefits from Marcellus Shale gas and a long history of chemical manufacturing, especially around Pittsburgh and the Ohio River Valley.
- Ohio: Roughly 2.8 million tons. Focused on polyethylene and PVC, with strong ties to automotive and packaging industries.
- California: About 2.5 million tons. More diverse in output-includes specialty plastics for medical devices and electronics-but less focused on bulk resin production.
These states all have one thing in common: access to cheap feedstock, either from pipelines, rail, or ports. But none have the scale, concentration, or integration that Texas does.
Why This Matters Beyond Numbers
When Texas produces more plastic than most countries, it affects everything from global pricing to environmental policy. The U.S. now exports over 10 million tons of plastic pellets annually-most of them from Texas. These pellets end up in packaging factories in Mexico, Southeast Asia, and Europe.
But there’s a cost. Plastic manufacturing is energy-intensive. Texas’s plants emit more than 100 million metric tons of CO2 each year-equivalent to adding 22 million cars to the road. Local communities near the Gulf Coast report higher rates of asthma and cancer clusters, linked to air pollutants like benzene and ethylene oxide.
Regulators have tried to tighten emissions rules, but industry lobbying has kept most standards voluntary. Environmental groups call it a “plastic corridor,” and say it’s time to rethink the entire model.
The Future of Plastic Manufacturing in the U.S.
Plastic production in the U.S. is still growing. Over 30 new petrochemical projects are in the pipeline, mostly in Texas and Louisiana. Many are backed by foreign investors looking to tap into cheap U.S. gas.
But the tide may be turning. Major brands like Coca-Cola, Unilever, and Walmart have pledged to reduce virgin plastic use by 2030. Recycling technology is improving, though it still only handles about 5% of plastic waste. Some companies are investing in chemical recycling-breaking plastic back down into feedstock-but it’s expensive and not yet scalable.
Texas will likely remain the leader for now. But if federal policy shifts toward carbon taxes or plastic bans, or if renewable energy makes green alternatives cheaper, the landscape could change fast. The state’s advantage isn’t just geography-it’s momentum. And momentum takes time to reverse.
What This Means for Consumers and Businesses
If you’re buying plastic packaging, you’re almost certainly holding something made from resin produced in Texas. Even if the final product was assembled in California or Illinois, the raw material likely came from the Gulf Coast.
For businesses, sourcing plastic means understanding where it’s made. Companies that want to reduce their carbon footprint are starting to ask suppliers: “Where is your resin produced?” Some are switching to recycled content or alternative materials like plant-based polymers. Others are working with local recyclers to close the loop.
For everyday people, it’s about awareness. That plastic bottle you toss in the bin? It probably started as gas from a well in West Texas. The more you understand that chain, the better choices you can make.
Which state produces the most plastic in the U.S.?
Texas produces the most plastic in the U.S., accounting for nearly 30% of the nation’s plastic resin output. In 2025, it manufactured over 14.5 million tons of plastic, primarily polyethylene and polypropylene, thanks to its access to cheap natural gas and dense petrochemical infrastructure along the Gulf Coast.
Why does Texas make so much plastic?
Texas has abundant, low-cost natural gas from the Permian Basin, which is the main feedstock for plastic production. The state also has deepwater ports for shipping, decades of industrial investment, and a regulatory environment that favors large-scale chemical manufacturing. Companies like Dow and Shell have built massive complexes here because it’s cheaper and more efficient than anywhere else in North America.
What percentage of U.S. plastic comes from Texas?
Texas produces about 30% of all plastic resin in the United States. In 2025, that amounted to over 14.5 million tons, more than the next three leading states combined. The rest is spread across Louisiana, Pennsylvania, Ohio, and California, but none come close to Texas’s output.
Is plastic production in Texas increasing or decreasing?
Plastic production in Texas is still increasing. Over 30 new petrochemical projects are under development or in construction, mostly along the Gulf Coast. These are driven by global demand for packaging and low U.S. gas prices. However, pressure from environmental regulations, corporate sustainability goals, and recycling innovation could slow growth in the coming decade.
What are the environmental impacts of plastic manufacturing in Texas?
Plastic plants in Texas emit over 100 million metric tons of CO2 annually and release toxic air pollutants like benzene and ethylene oxide. Communities near the Houston Ship Channel and Louisiana’s Cancer Alley report higher rates of respiratory illness and cancer. While federal regulations exist, enforcement is weak, and many emissions are self-reported by companies. Environmental groups are pushing for stricter oversight and a shift away from virgin plastic production.
