A polyethylene encapsulation system for treatment of low-level radioactive, hazardous, and mixed wastes has been developed at Brookhaven National Laboratory. Polyethylene has several advantages compared with conventional solidification/stabilization materials such as hydraulic cements. Waste can be encapsulated with greater efficiency (i.e., more waste encapsulated per drum) and with better waste form performance than is possible with hydraulic cement. The properties of polyethylene relevant to its long-term durability in storage and disposal environments are reviewed. Response to specific potential failure mechanisms including biodegradation, radiation, chemical attack, flammability, environmental stress cracking, and photodegradation are examined. These data are supported by results from extensive waste form performance testing including compressive yield strength, water immersion, thermal cycling, teachability of radioactive and hazardous species, irradiation, biodegradation, and flammability. The bench-scale process has been successfully tested for application with a number of specific "problem" waste streams including nitrate salts, sludges, incinerator ash, reactor-generated evaporator concentrates (sodium sulfate and boric acid), and ion exchange resins. A production-scale technology demonstration of polyethylene encapsulation of nitrate salt waste, sponsored by the Department of Energy (DOE), Office of Technology Development (OTD), Division of Demonstration, Testing and Evaluation (DT&E) is planned in conjunction with Rocky Flats Plant. In support of the technology demonstration, a scale-up feasibility test was conducted by processing simulated nitrate salt waste with a production-scale extrusion system. Output rates in excess of 454 kg/hr (1000 lb/hr) were achieved, ana process data were in close agreement with bench-scale parameters. Quality assurance and performance testing of the resulting waste form confirmed scale-up feasibility. Use of this system at Rocky Flats Plant can result in over 70% fewer drums processed and shipped for disposal, compared with optimal cement formulations. Based on the current Rocky Flats production of about 1 x 10 6 kg (2.2 x 10 6 lbs) of nitrate salt per year, polyethylene encapsulation can yield an estimated annual savings between $1.5 million and $2.7 million, compared with conventional hydraulic cement systems.