Cross-linked zein has been produced using glyoxal (GLY) as the cross-linking reagent via reactive extrusion for the first time in a twin screw extruder using dilute sodium hydroxide as catalyst. Tri(ethylene glycol) was used as a plasticizer for various items. The extrudate was then ground and processed using either compression or injection molding. At the highest level of GLY (6%), tri(ethylene glycol) was used at 10% as a plasticizer to allow further processing to take place. With this formulation, samples could be obtained from the injection mold, however, the samples did not hold their molded shape due to the elasticity of the sample at the mold temperature. When lower levels of GLY were used, injection molded sample bars of similar quality to control were obtained. The physical properties of these samples were similar to control. At GLY levels of 1.75% and higher, the samples were resistant to dissolution by acetic acid. (C) 2009 Wiley Periodicals, Inc. J Appl Polym Sci 113: 1828-1835, 2009