Characterization of Composition and Structure-Property Relationships of Commercial Post-Consumer Polyethylene and Polypropylene Recyclates

Comparing End-of-Life Vehicle (ELV) and Packaging-Based Recyclates as Components in Polypropylene-Based Compounds for Automotive Applications

Increasing recycled plastic content in cars to 25% by 2030 is one of the key measures for decarbonizing the automotive industry defined by the European Commission. This should include the recovery of plastics from end-of-life vehicles (ELVs), but such materials are hardly used in compounds today. To close the knowledge gap, two ELV recyclate grades largely based on bumper recycling were analyzed in comparison to a packaging-based post-consumer recyclate (PCR). The composition data were used to design polypropylene (PP) compounds for automotive applications with virgin base material and mineral reinforcement, which were characterized in relation to a commercial virgin-based compound. A compound with a 40 wt.-% ELV-based bumper recyclate can exceed one with just a 25 wt.-% packaging-based recyclate in terms of stiffness/impact balance. While the virgin reference can nearly be matched regarding mechanics, the flowability is not reached by any of the PCR compounds, making further development work necessary.

A New Sustainable PPT Coating Based on Recycled PET to Improve the Durability of Hydraulic Concrete

A new, sustainable polypropylene terephthalate (PPT) coating was synthesized from recycled polyethylene terephthalate (PET) and applied onto a hydraulic concrete substrate to improve its durability. For the first step, PET bottle wastes were ground and depolymerized by glycolysis using propylene glycol (PG) in a vessel-type reactor (20-180 °C) to synthesize bis(2-hydroxypropyl)-terephthalate (BHPT), which was applied as a coating to one to three layers of hydraulic concrete substrate using the brushing technique and polymerized (150 °C for 15 h) to obtain PPT. PET, BHPT, and PPT were characterized by FT-IR, PET, and PPT using TGA, and the PPT coatings by SEM (thickness), ASTM-D3359-17 (adhesion), and water contact angle (wettability). The durability of hydraulic concrete coated with PPT was studied using resist chloride ion penetration (ASTM-C1202-17), carbonation depth at 28 days (RILEM-CPC-18), and the absorption water ratio (ASTM-C1585-20). The results demonstrated that the BHPT and PPT were synthetized (FT-IR), and PPT had a similar thermal behavior to PET (TGA); the PPT coatings had good adhesion to the substrate, with thicknesses of micrometric units. PPT coatings presented hydrophilic hydrophilic behavior like PET coatings, and the durability of hydraulic concrete coated with PPT (2-3 layers) improved (migration of chloride ions decreased, carbonation depth was negligible, and the absorption water ratio decreased).

Influence of Biogenic Material Content on the Biodegradability of Styrene-Butadiene Composites with Incorporated Chlorella vulgaris Biomass

Bio-fillers are intensively studied for advanced polymer composite circular design and production. In this context, the algal biomass may be considered an important and relatively low-cost resource, when harvested as a by-product from wastewater treatment plants. The biomass of the algal species Chlorella vulgaris is frequently used in this type of environmental process, and its macro constituents' composition ranges from around 15-25% carbohydrates, 10-20% lipids, and 50-60% proteins. Poly (styrene-butadiene-styrene) (SBS) copolymers have a matrix composed of glassy polystyrene domains connected by flexible polybutadiene segments. Although the physical-mechanical properties of SBS copolymers recommend them for many industrial applications, they have the drawback of low biodegradability. This study aimed to assess the aerobic biodegradability of polymer composites by integrating biomass from Chlorella vulgaris at varying mass percentages of 5, 10, and 20% into SBS copolymer composites. Biodegradation tests were conducted under industrial composting conditions (58 °C and 50% relative humidity) for 180 days. The biodegradability of materials was evaluated by measuring the CO2 produced in each vessel during the study period. Potential correlations between the amount of carbon dioxide released and the percentage of biomass added to the polymer matrix were examined. Structural and morphological changes were assessed using Fourier Transform infrared spectroscopy (FTIR), thermal analysis (DSC), and scanning electron microscopy (SEM). Physical and chemical testing revealed a decrease in sample density after the industrial composting test, along with noticeable changes in melt flow index (MFI). The observed physical and chemical changes, coupled with FTIR, SEM, and DSC data, indicate increased cross-linking and higher porosity in biodegraded polymer structures with higher biomass content. This behavior is likely due to the formation of cross-linked connections between polymer chains and polypeptide chains resulting from protein degradation, enhancing connections between polystyrene units facilitated by peptide bonds with the benzene units of the styrene blocks within the polymer matrix.

Characterisation of formulated high-density poly(ethylene) by magic angle spinning nuclear magnetic resonance

High-density poly(ethylene) (HDPE) is an important class of polymer used extensively in plastic packaging as well as numerous other applications. HDPE has a structure that consists of crystalline (monoclinic and orthorhombic) and amorphous domains. Here, we exploit a range of approaches focusing on magic angle spinning (MAS) nuclear magnetic resonance (NMR) aimed at comparing the effect of the HDPE sample formulation (cutting, shaving and cryomilling), from the commercially available manufactured pellets, into these domains and their quantification. 13C cross polarisation (CP) experiments reveal that these formulated HDPEs are qualitatively different and 13C CP build-up curves and 13C direct excitation experiments enable the content of each domain to be obtained, pointing to an increase of monoclinic domain at the expense of the orthorhombic one upon increased processing. The crystallinity contents obtained compared, in some cases, favourably with those obtained by differential scanning calorimetry (DSC) data. These results provide evidence that the manner of preparation of HDPE pellets modifies the concentration of the various domains and suggest that care should be taken during processing.

Analysis of different polypropylene waste bales: Evaluation of the source material for PP recycling

The use of the polypropylene (PP) recyclates in certain processing methods and applications is still limited by their quality. The high melt flow rate (MFR) and the inconsistent properties of recyclates are common obstacles to their use. Therefore, this work aims to identify possible reasons for the low and inconsistent quality of PP recyclates depending on the source material in PP waste bales. The levels of polymeric and non-polymeric contaminants were assessed. As mixing of different PP grades is an issue for the MFR, the proportions of the different processing grades were also investigated and the potential of sorting by processing method to produce lower MFR recyclates was assessed. The analysis showed that the waste bales, although pre-sorted, still contained high amounts of contaminants. Injection moulding was found to be the predominant processing method in the bales, explaining the high MFR of PP recyclates. However, a sufficiently high amount of low MFR products was found in the bales, which seems promising for the production of low MFR recyclates. Seasonal variations in the composition of the waste bales were identified as one of the reasons for the inconsistent qualities of recyclates. These results highlight the importance of proper sorting and treatment of PP waste bales prior to reprocessing in order to obtain high-quality recycled products.

Impact of Multiple Reprocessing on Properties of Polyhydroxybutyrate and Polypropylene

Biobased plastics have the potential to be sustainable, but to explore their circularity further, current end-of-life options need to be broadened. Mechanical recycling is one of the most accepted methods to bring back plastics into the loop. Polyhydroxybutyrates (PHBs) are biobased and biodegradable in nature with promising properties and varied applications in the market. This study focuses on their potential for mechanical recycling by multiple extrusion cycles (E1-E5) and multi-faceted characterization of the virgin (V) and reprocessed materials from E1 to E5. The behavior is compared to polypropylene (PP) as a reference with a similar property profile, which has also been reprocessed five times. The thermal properties of both series showed a stable melting point and thermal decomposition temperature from thermal analyses (differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA)). However, a steady increase in the degree of crystallinity was observed which could counterbalance the decrease in molecular weight due to repeated extrusion measured by gel permeation chromatography and resulted in similar values of tensile strength across the cycles. The strain at break was impacted after the first extrusion, but no significant change was observed thereafter; the same was observed for impact strength. Even in scanning electron microscopy (SEM) images, virgin and E5 samples appeared similar, showing the stability of morphological characteristics. Fourier transform infrared spectroscopy (FTIR) results revealed that no new groups are being formed even on repeated processing. The deviation between the PHB and PP series was more predominant in the melt mass flow rate (MFR) and rheology studies. There was a drastic drop in the MFR values in PHB from virgin to E5, whereas not much difference was observed for PP throughout the cycles. This observation was corroborated by frequency sweeps conducted with the parallel plate method. The viscosity dropped from virgin to E1 and E2, but from E3 to E5 it presented similar values. This was in contrast to PP, where all the samples from virgin to E5 had the same values of viscosity. This paper highlights the possibilities of mechanical recycling of PHB and explains why future work with the addition of virgin material and other additives is an area to be explored.

Fourier Transform Mid-Infrared Spectroscopy (FT-MIR) as a Method of Identifying Contaminants in Sugar Beet Production Process-Case Studies

Food safety has received considerable attention in recent years. Methods for rapid identification of a variety contaminants in both the final product and the manufacturing process are constantly developing. This study used Fourier Transform Mid-Infrared Spectroscopy (FT-MIR) spectroscopy to identify various contaminants endangering white sugar production. It was demonstrated that inorganic compounds (calcium carbonate-CaCO₃), plastic contaminants (polypropylene), and oily contaminants (compressor sealing and lubrication lubricant) can be identified with a high degree of precision. FT-MIR spectroscopy was proved to be a useful technique for detecting sugar contaminants rapidly and precisely even without the application of a sophisticated spectra analysis. Commercial databases of reference spectra usage significantly simplify and facilitate the application of this method.

Polyolefin Recyclates for Rigid Packaging Applications: The Influence of Input Stream Composition on Recyclate Quality

In order to shift to a circular plastics economy, high quality recyclates are required to effectively substitute virgin materials. Current approaches to empirically quantify the substitutability for recyclates are mainly limited by the abundance of virgin material grades along with a lack of adequate application-specific property profiles. In contrast, this work aims for a holistic analysis of the substitution potential of polyolefin recyclates intended for rigid packaging applications. This approach is fundamentally based on the classification of virgin polyolefins into different application-specific sub-groups with defined property windows derived from supplier data sheets, which allows for a generalization within one polymer type without neglecting the various available material grades. Moreover, the findings should provide valuable information for improvements of quality-defining process steps along the value chain of mechanical recycling. Therefore, it is of great importance to correlate the input stream composition of the investigated recyclates with the obtained qualities. The investigation of the substitution potential for selected recyclates clearly highlights the necessity of functional recycling for enhanced quality levels, which especially affects the sorting step in the recycling value chain. This work illustrates that a homogeneous waste stream directly correlates with a high substitution potential. Thus, the development of economically viable sorting strategies which take the functionality of plastic waste products into account must be targeted in future research. Furthermore, the development of detailed application-specific property windows in a joint effort with manufacturers should be pursued, as it allows for a meaningful empirical quantification of the substitutability for recyclates obtained from mechanical recycling.

From Bottle Caps to Frisbee-A Case Study on Mechanical Recycling of Plastic Waste towards a Circular Economy

This study demonstrates an open-loop recycling process of a specific post-consumer plastic waste stream. The targeted input waste material was defined as high-density polyethylene beverage bottle caps. Two methods of waste collection, informal and formal, were employed. Thereafter, materials were hand-sorted, shredded, regranulated, and then injection-molded into a flying disc (i.e., frisbee) as a pilot product. To observe the potential changes in the material throughout the entire recycling process, eight different test methods including melt mass-flow rate (MFR), differential scanning calorimetry (DSC), and mechanical tests were carried out on the various material states. The study showed that the informal collection led to a relatively higher purity in the input stream, which also appeared to have a 23% lower MFR value compared to that of the formally collected materials. The DSC measurements revealed a cross-contamination by polypropylene, which clearly affected the properties of all investigated materials. The cross-contamination led to a slightly higher tensile modulus in the recyclate, while the Charpy notched impact strength declined after processing by approximately 15% and 8% compared to those of the informal and formal input materials, respectively. All materials and the processing data were documented and stored online as a practical implementation of a digital product passport as a potential digital traceability tool. Furthermore, the suitability of the resulting recyclate to be used in transport packaging applications was also investigated. It was found that a direct replacement of virgin materials for this specific application is not possible without proper material modification.

From Electronic Waste to 3D-Printed Product, How Multiple Recycling Affects High-Impact Polystyrene (HIPS) Filament Performances

The rapid growth of the electronics industry is producing excessive electronic waste. One of the common types of materials in electronic waste is high-impact polystyrene (HIPS). In this study, HIPS from electronic waste was recycled through an extrusion process and used as a 3D print filament. The effects of recycling on printability, physical properties, and mechanical properties in horizontal and vertical directions were examined. It was found that until the fourth-cycle, mechanical properties such as horizontal tensile strength, horizontal flexural strength, vertical flexural strength, and vertical impact strength were comparable with virgin commercial filament. In addition, the vertical flexural modulus in the fourth cycle increased by 77.28%. However, the density of recycled HIPs' first to the fourth cycle slightly decreased by 10.6%, and the melt flow rate increased by 20.3%. It was also observed that until the third cycle, the effect of the reprocessing steps was insignificant on the defect of the 3D-printed product. In general, the experiments show various results, mainly in mechanical properties. Nevertheless, recycled HIPS filaments are comparable to or better than commercial ones in some cases. As a result, recycled HIPS filaments hold the potential to be considered as an alternative to other types of 3D print filaments.

Simultaneous Modification of Properties Relevant to the Processing and Application of Virgin and Post-Consumer Polypropylene

Post-consumer recyclates often have a property profile that results from mixing a variety of products, which are made from different materials, produced by different processing methods, and coming from applications with different lifetimes. This usually leads to a mixture of all these material properties in the recycling process. In contrast, virgin materials are specifically designed for applications and thus offer all the necessary properties for the intended products. In order to be able to use recycled materials for specific and demanding applications, not only the viscosity, which is important for processing and often varies greatly with recyclates, but also the mechanical properties, particularly the tensile modulus and impact strength, must be adjusted. For this purpose, various virgin materials of polypropylene homopolymers, random copolymers, and block copolymers with different flowabilities were mixed in different proportions and their properties were determined. The flowability of homopolymers and random copolymers in the blend behaved very similarly, while block copolymers exhibited a different behavior in some cases. By incorporating homopolymers into blends, the stiffness of the resulting material blend can be very well adjusted. The addition of random copolymers can increase strain at break, and the addition of block copolymers results in a significant increase in impact strength. In numbers, the maximum adjustment range for tensile modulus, yield stress, strain at break, and impact strength are 880 MPa, 14 MPa, 185%, and 6.9 kJ/m², respectively. While a good and reliable prediction of property profile is possible for polymer blends with different virgin materials, the resulting material properties for polymer blends of virgin and recycled materials are also influenced by impurities. In this work, however, a good prediction was also achieved for recyclate blends.

Developing Post-Consumer Recycled Flexible Polypropylene and Fumed Silica-Based Nanocomposites with Improved Processability and Thermal Stability

Collection and mechanical recycling of post-consumer flexible polypropylene packaging is limited, principally due to polypropylene being very light-weight. Moreover, service life and thermal-mechanical reprocessing degrade PP and change its thermal and rheological properties according to the structure and provenance of recycled PP. This work determined the effect of incorporating two fumed nanosilica (NS) types on processability improvement of post-consumer recycled flexible polypropylene (PCPP) through ATR-FTIR, TGA, DSC, MFI and rheological analysis. Presence of trace polyethylene in the collected PCPP increased the thermal stability of the PP and was significantly maximized by NS addition. The onset decomposition temperature raised around 15 °C when 4 and 2 wt% of a non-treated and organically modified NS were used, respectively. NS acted as a nucleating agent and increased the crystallinity of the polymer, but the crystallization and melting temperatures were not affected. The processability of the nanocomposites was improved, observed as an increase in viscosity, storage and loss moduli with respect to the control PCPP, which were deteriorated due to chain scission during recycling. The highest recovery in viscosity and reduction in MFI were found for the hydrophilic NS due to a greater impact of hydrogen bond interactions between the silanol groups of this NS and the oxidized groups of the PCPP.

Polypropylene Post-Consumer Recyclate Compounds for Thermoforming Packaging Applications

Polypropylene (PP) plastic packaging waste consists of a variety of different plastic packaging products with a great span in rheological and mechanical behavior. Therefore, the resulting post-consumer recyclates usually show melt mass-flow rates (MFR) in the region of injection molding grades and intermediate mechanical properties. High-quality packaging applications demand a distinct property profile that is met by tailor-made PP grades and cannot be met by recyclates with intermediate performance. One such application with high market volume is high-stiffness thermoforming trays. The aim of this research was to blend intermediate-performance recyclates with a virgin PP grade to obtain compounds that fulfill the rheological and mechanical demands of this application. Three commercially available PP post-consumer recyclates were acquired and compounded with different blending ratios with a high stiffness, low MFR virgin PP grade. As the pure recyclates show different rheological properties, the blending ratios had to be adapted for each of them to fit into the MFR range of 2-4 g/10 min which is desirable for thermoforming applications. The resulting PP recyclate compounds show a distinct correlation of recyclate content with rheological and mechanical performance. However, the resulting property profile was directly dependent on the performance of the originally used recyclate. The best-performing recyclate could be used in a blending ratio of 65 m% recyclate content while adhering to both property limits, the MFR of 2-4 g/10 min and the lower bound tensile stiffness of 1500 MPa.

Assessment of Commercially Available Polyethylene Recyclates for Blow Molding Applications by a Novel Environmental Stress Cracking Method

The transition to a circular economy has a major impact on waste management and the reuse of materials. New mandatory recycling targets for plastics will lead to a high availability of recyclates. For these recyclates, useful applications need to be found. One potential application for recyclates is blow molding bottles as packaging for non-food contents. This study investigates commercially available post-consumer high-density polyethylene recyclates together with virgin blow molding grades in terms of their short-term mechanical properties and environmental stress cracking resistance. While the short-term mechanical properties showed only slightly lower performance than the tested virgin grades, the overall environmental stress cracking failure times of the recyclates were much lower compared to virgin materials, even though the crack-growth kinetics could be similar. Although neither the tensile nor the notched impact strength results of the two polyethylene recyclates revealed large differences, the stress intensity-factor-dependent crack-growth rates of both materials were significantly different.

Mechanical and Thermal Properties of Mixed PE Fractions from Post-Consumer Plastic Packaging Waste

The functional properties of recycled post-consumer flexible polyethylene packaging waste have been studied using materials collected and sorted at a large-scale facility in Sweden. The studied fraction was used both as received and after simple laboratory washing in water with added sodium hydroxide at 40 °C. The materials were melt-compounded with a twin-screw extruder using two different temperature profiles and two screw configurations and injection-molded into slabs, whose thermal and mechanical properties were assessed. The results showed that the mechanical properties of injection-molded samples were not changed significantly either by the washing or by the temperature or screw configuration used in the compounding. Washing reduced the viscosity and molecular mass to a minor extent. As expected, the ash content of the compounded pellets was reduced by washing. The thermo-oxidative stability decreased with increasing compounding temperature and with washing.

Polypropylene Pipe Compounds with Varying Post-Consumer Packaging Recyclate Content

The high recycling targets set by the European Commission will create an increased availability of polypropylene (PP) post-consumer recyclates (PCRs). However, no regulations mandate the use of recycled PP (rPP), so the industry is challenged to explore possibilities to utilize such materials. One option, as suggested by the European Commission, is the introduction of rPP in pipe applications. According to existing standards, the use of recyclate is not allowed in pressurized gas and drinking water systems. However, many other pipe and underground applications, such as stormwater systems, open the increased use of PCRs. Additionally, even for less-demanding applications, such as non-pressure sewage systems, highly durable solutions are needed to cover the requested lifetime and request an ambitious property profile to fulfill the application needs that cannot be met by PP packaging materials and even less by PCRs thereof. Hence, this work explores the possible use of commercially available PCRs out of polypropylene from packaging applications in compounds together with virgin PP pipe grades to meet the demands for less-demanding applications. Two different commercially available rPPs and one commercially available recycled polyolefin (rPO) from mixed polyethylene and PP waste were acquired and, together with two predefined virgin PP pipe grades, were blended to compounds in the range of 10 m%, 20 m%, and 30 m% recyclate content. The compounds and three virgin PP pipe grades, acting as benchmarks, were tested in terms of short- and long-term mechanical performance as well as for many other physical properties. All of the compounds showed good results regarding fatigue crack (FCG) resistance with virgin polymer as the reference. The factors influencing FCG resistance, such as melt flow rate and polyolefin cross-contamination, were thoroughly investigated as the used virgin grades and recyclates cover a broad range of these properties.

Application of Mixing Rules for Adjusting the Flowability of Virgin and Post-Consumer Polypropylene as an Approach for Design from Recycling

To enable the use of recyclates in thermoformed polypropylene products with acceptable optical appearance and good mechanical stability, a multilayer structure of virgin and recycled material can be used. When producing multilayer films with more than two layers, the used materials should have similar melt flow properties to prevent processing instabilities. In the case of a three-layer film, post-consumer recyclates are often hidden in the core layer. Due to the inconsistent melt flow properties of post-consumer recyclates, the adjustment of the melt flow properties of the core layer to those of the outer layers has to be realized by blending with virgin materials. In order to understand the effect of mixing with a virgin material with a certain pre-defined melt flow rate (MFR), material mixtures with different mixing partners from various sources were realized in this study. Hence, the pre-defined virgin material was mixed with (i) virgin materials, (ii) artificial recyclates out of a mixture of different virgin materials, and (iii) commercially available recyclates. These blends with mixing partner contents ranging from 0–100% in 10% increments were prepared by compounding and the MFR of each mixture was determined. For a mathematical description of the mixing behavior and furthermore for a proper MFR prediction of the material mix, existing mixing rules were tested on the three pre-defined sample groups. Therefore, this paper shows the applicability of different mixing rules for the prediction of the MFR of material blends. Furthermore, a new mixing rule was developed using symbolic regression based on genetic programming, which proved to be the most accurate predictive model.

Short- and Long-Term Performance of Pipe Compounds Containing Polyethylene Post-Consumer Recyclates from Packaging Waste

The polymer industry is pushed to present solutions that lead to a circular plastics economy. High plastic packaging waste recycling targets will eventually lead to a high availability of packaging material recyclates. Although the use of polyethylene terephthalate (PET) recyclates is prescribed by regulations to be used in new PET bottles, no such regulation prescribes the use of polyethylene recyclate (rPE) in new products. One possibility of using rPE, which is considered by the European Union, is the use within pipe materials. Pipe applications demand a certain property profile, most prominently a high slow crack growth (SCG) resistance, which is not met by most packaging materials or recyclates made from it. Hence, this work investigates the use of commercially available post-consumer recyclates out of high-density polyethylene from packaging applications in compounds together with high SCG-resistant virgin PE pipe material with a PE100-RC specification. Two rPEs were acquired from German producers and blended to compounds consisting of 25 m%, 50 m% and 75 m% recyclate. These compounds, together with the pure recyclates and several virgin pipe materials acting as benchmarks were tested in terms of short- and long-term mechanical performance and with other basic characterization methods. Several compounds exceeded the performance of one tested virgin PE pipe material, an injection molding PE80 grade, in several categories. The content of recyclate needed to outperform this benchmark grade was mostly dependent on the resulting melt flow rate (MFR) of the compound and thus also of the MFR of the pure recyclate. Furthermore, different levels of polypropylene contaminations within the recyclates resulted in differently contaminated compounds. This is proved to influence the SCG resistance too, as compounds of similar MFRs but with different SCG resistances were found.

Feasibility Study of the Flatness of a Plastic Injection Molded Pallet by a Newly Proposed Sequential Valve Gate System

The investigation of plastic pallet molding, assisted by a sequential valve gate system, has not yet been performed due to the limitations of the pallet scale. Furthermore, at present, the application of recycled plastics by chemical industries has become extremely popular around the world. This study aimed to determine pallet flatness experimentally and numerically using recycled polypropylene with a large-scale pallet. Short-shot testing on injection molding was performed to obtain short-shot samples for confirmation of the flow front during simulated filling. The real injected pallet profile, which was measured by an ATOS, was compared after confirmation to the numerical profile of the pallet. The pallet’s flatness was accurately compared to the real experimental and numerical results. By adjusting the temperature of the cooling channel within the cavity plate to 55 °C, the flatness of the pallet achieved by the newly proposed sequential valve gate-opening scheme was about 7 mm, which meets the height directional warpage standard determined by the pre-set sequential scheme. The numerical flatness is in line with existing flatness values for pallets. Furthermore, the proposed cooling temperature gives the highest yield in terms of pallet molding from the perspective of the stakeholders.

Challenges and Opportunities for Recycled Polyethylene Fishing Nets: Towards a Circular Economy

Plastic waste generation has become an important problem that critically affects marine and oceans environments. Fishing nets gear usually have a relatively short lifespan, and are abandoned, discarded and lost, what makes them one of the largest generators of ocean plastic waste. Recycled polyolefin resins from fishing nets (rFN), especially from polyethylene (PE), have poor properties due to the presence of contaminants and/or excessive degradation after its lifetime. These reasons limit the use of these recycled resins. This work aims to study the incorporation of recycled fishing nets PE-made to different grades of virgin PE, in order to evaluate the potential use of these rFN in the development of new products. The recovered fishing nets have been fully characterized to evaluate its properties after the collection and recycling process. Then, different PE virgin resins have been mechanically blended with the recovered fishing nets at different recycling contents to study its feasibility for fishing nets or packaging applications. Critical mechanical properties for these applications, as the elongation at break, impact strength or environmental stress cracking resistance have been deeply evaluated. Results show important limitations for the manufacture of fibers from recycled PE fishing nets due to the presence of inorganic particles from the marine environment, which restricts the use of rFN for its original application. However, it is proved that a proper selection of PE raw resins, to be used in the blending process, allows other possible applications, such as non-food contact bottles, which open up new ways for using the fishing nets recyclates, in line with the objectives pursued by the Circular Economy of Plastics.

Polypropylene Contamination in Post-Consumer Polyolefin Waste: Characterisation, Consequences and Compatibilisation

Plastic recycling strikes a balance between functional, mass producible products and environmental sustainability and is pegged by governments for rapid expansion. However, ambitious targets on recycled material adoption across new markets are at odds with the often heterogenous properties of contaminated regranulates. This study investigated polypropylene (PP) contamination in post-consumer low-density polyethylene (PE-LD) and mixed polyolefin (PO) regranulates. Calibration curves were constructed and PP content, its effect on mechanical properties and property recovery in compatibilised material assessed. FT-IR band ratios provided more reliable estimations of PP content than DSC melt enthalpy, which suffered considerable error for PP copolymers. PE-LD regranulates contained up to 7 wt.% PP contamination and were considerably more brittle than virgin PE-LD. Most mixed PO regranulates contained 45-95 wt.% PP and grew more brittle with increasing PP content. Compatibilisation with 5 wt.% ethylene-based olefin block copolymer resulted in PE-LD blends resembling virgin PE-LD and considerable improvements in the properties of mixed PO blends. These results illustrate the prevalence of PP in recycled PE, challenges associated with its quantification, effect on mechanical properties, and compatibilisation viability, thereby representing an important step towards higher quality regranulates to meet the recycling demands of tomorrow.

Leaching and VOC Emission Tests of Polymer Composites Produced from Post-Consumer Waste in Terms of Application in the Construction Sector

One of the existing priorities of the European Union is to search for rational waste management and to keep such waste in the economic cycle, while meeting the highest safety requirements. The paper presents the results of environmental tests of composites based on the polyethylene (rPE) and polypropylene (rPP) matrix and reinforced with cellulose fibres (newsprint, NP). Raw materials were obtained by recycling post-consumer waste such as beverage bottles and newsprint. The composites were tested for their potential use as materials in cladding panels and acoustic barriers. Given that normative documents for these products do not define specific environmental requirements, the composites were tested for the release of dangerous substances, such as anions of inorganic compounds, heavy metals, volatile organic compounds (VOCs), and their impact on the environment. A detailed in-depth analysis of the mechanisms of release of substances (diffusion, dissolution, surface leaching and depletion) from the rPP/NP composite into surface water, groundwater and soil was carried out. In turn, emission of VOCs from the rPE (low-density:high-density (LD:HD)-50:50) and rPE (LD:HD-30:70) composites into indoor air was also carried out. Raw materials in the form of granulates and loose cellulose fibres, used to produce the composites, were also tested for their environmental impact.