SIU Carbondale Researchers Unveil 3D-Printed Protein Cookies from Recycled Plastic

This research addresses two critical global challenges: food shortages and plastic waste.

• On August 25, 2026, researchers at Southern Illinois University Carbondale unveiled µBites, 3D-printed cookies made from recycled PET plastic and agricultural waste.
• The project, led by Lahiru Jayakody and Sandhya Jayasekara, utilizes engineered yeast to convert waste into edible protein supplements.
• Prototypes were showcased at the American Chemical Society Fall 2026 meeting, with safety metrics meeting NASA standards but pending human taste tests.

• NASA's Deep Space Food Challenge inspired this initiative, aiming to develop sustainable food technologies for long-duration space missions.
• Projected food demand is expected to increase by 35–56% by 2050, necessitating innovative solutions to meet nutritional needs.
• Plastic waste accumulation poses a significant environmental threat, with millions of tons of PET plastic entering landfills annually.

The development of µBites represents a convergence of food technology and environmental sustainability. The process begins with the oxidative hydrothermal dissolution of PET plastic, commonly found in water bottles, combined with agricultural biomass such as corn stalks and leaves. This method employs high-temperature, high-pressure water and oxygen to break down the materials into carbon-rich molecules suitable for microbial conversion.

The engineered yeast strains play a crucial role in this transformation. Saccharomyces cerevisiae, a well-known yeast in baking and brewing, is utilized to convert ferulic acid into vanillin, imparting a pleasant vanilla flavor to the cookies. Meanwhile, Rhodosporidium toruloides, another engineered yeast, is adapted to thrive on ethylene glycol, producing beta-carotene, a precursor to vitamin A. This innovative approach not only generates proteins and fats but also incorporates essential flavor compounds, resulting in a nutritious and palatable product.

The final step involves creating a printable slurry that combines these nutrients with fiber, starch, and sweeteners. This mixture is extruded through a 3D printer to form disc-shaped cookies branded as µBites. The research team has demonstrated that the safety metrics of these cookies meet NASA's stringent standards, although human taste tests are still pending institutional approval.

The implications of this research extend beyond space missions. With global food demand projected to rise significantly, the ability to convert waste materials into edible products could provide a sustainable solution to food shortages. Additionally, addressing plastic pollution through innovative recycling methods aligns with global sustainability goals. However, the transition from prototype to commercialization faces challenges, particularly regarding public acceptance of food derived from recycled plastics.

• Food industry professionals: They may need to adapt to new sourcing and production methods.
• Environmental advocates: They will monitor the impact on plastic waste reduction.
• Consumers: Public perception of edible products made from recycled materials will influence market acceptance.
• Space agencies: They could benefit from sustainable food solutions for long-duration missions.

• Institutional approvals: The timeline for human taste testing will indicate the project's readiness for commercialization.
• Cost reduction efforts: The current production cost of $60 per kilogram needs to decrease for broader market viability.
• Public acceptance studies: Understanding consumer attitudes towards plastic-derived food products will be crucial for market entry.