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.

Evaluation of mixed #3-7 plastic waste from material recovery facilities (MRFs) in the United States

Plastic recycling rates are still low in the United States (U.S.), with less than 10% of municipal solid waste (MSW) plastic being recycled. Most unrecycled plastics are identified by Resin Identification Codes (RIC) from #3-7, which are commonly destined for landfill or waste-to-energy facilities (WTE). Therefore, the composition and quality of outbound bales containing #3-7 plastics were assessed to understand the potential to increase recycling rates. Three bales were sourced from three different Material Recovery Facilities (MRFs) located in the United States. Each bale was manually sorted and characterized for quality and performance via multiple plastic characterization techniques. Considerable differences in bale composition were observed between MRFs, which correlated with the technology used by each MRF in the sorting process. The differences were substantial in the residual levels of poly(ethylene terephthalate) (PET) and high-density polyethylene (HDPE), which are highly desired for mechanical recycling processes and not expected in #3-7 plastics bales. Traditional recycling processes including washing, extrusion, and injection molding of the sorted material were employed prior to the physical, thermal, and molecular characterization. Despite differences in bale composition by plastic type, some polymer properties were similar across MRFs. This research suggests that landfill-diverted mixed plastic waste can be utilized in the mechanical recycling of currently unrecycled materials, as processes can be designed to work with consistent polymer properties. It also highlights the need to upgrade the sorting systems to prevent waste feedstocks, which can be recycled with current technologies, from contaminating other plastic streams or reach landfills.

Suitability of MRF Recovered Post-Consumer Polypropylene Applications in Extrusion Blow Molded Bottle Food Packaging

Polypropylene (PP) is one of the most abundant plastics used due to its low price, moldability, temperature and chemical resistance, and outstanding mechanical properties. Consequently, waste from plastic materials is anticipated to rapidly increase with continually increasing demand. When addressing the global problem of solid waste generation, post-consumer recycled materials are encouraged for use in new consumer and industrial products. As a result, the demand is projected to grow in the next several years. In this study, material recovery facility (MRF)-recovered post-consumer PP was utilized to determine its suitability for extrusion blow molded bottle food packaging. PP was sorted and removed from mixed-polymer MRF-recovered bales, ground, trommel-washed, then washed following the Association of Plastics Recyclers' protocols. The washed PCR-PP flake was pelletized then manually blended with virgin PP resin at 25%, 50%, 75, and 100% PCR-PP concentrations and fed into the extrusion blow molding (EBM) machine. The EBM bottles were then tested for physical performance and regulatory compliance (limits of TPCH: 100 μg/g). The results showed an increased crystallization temperature but no practical difference in crystallinity as a function of PCR-PP concentrations. Barrier properties (oxygen and water vapor) remained relatively constant except for 100% MRF-recovered PCR-PP, which was higher for both gas types. Stiffness significantly improved in bottles with PCR-PP (p-value < 0.05). In addition, a wider range of N/IAS was detected in PCR-PP due to plastic additives, food additives, and degradation byproducts. Lastly, targeted phthalates did not exceed the limits of TPCH, and trace levels of BPA were detected in the MRF PCR-PP. Furthermore, the study's results provide critical information on the use of MRF recovered in food packaging applications without compromising performance integrity.

Integrating stabilizer efficiency of secondary antioxidants to thermal, rheological, optical characterization and filterability study of polypropylene

The framework of the present study is based on investigation of different types of phosphorus based secondary antioxidants and their role in stabilization of polypropylene. Three different chemical entities i.e., Tris (2,4-di-tert-butylphenyl) phosphite, Tetrakis (2,4-di-tert-butylphenyl)-4,4-biphenyldiphosphonite and Bis (2,6-di-tert-butyl-4-methylphenyl pentaerythritol-diphosphite) have been studied for its efficiency as a secondary antioxidants or processing stabilizer. Thermal stability of polymer is predicted using degradation kinetics study and correlated with it’s optical, thermal and rheological response. To further evaluate performance of secondary antioxidants, thermogravimetry analysis was performed for polypropylene at three different heating rates and processed for iso-conversional analysis to get the kinetic parameters. Oxidation induction data and kinetic parameters have been related with efficiency of the stabilizers. Filtration study was also carried out to understand the efficacy of stabilizers during secondary process. Die pressure build up in filtration study is quantified and related with performance of secondary antioxidants.

Influence of Stabilization Additive on Rheological, Thermal and Mechanical Properties of Recycled Polypropylene

To decrease the amount of plastic waste, the use of recycling techniques become a necessity. However, numerous recycling cycles result in the mechanical, thermal, and chemical degradation of the polymer, which leads to an inefficient use of recycled polymers for the production of plastic products. In this study, the effects of recycling and the improvement of polymer performance with the incorporation of an additive into recycled polypropylene was studied by spectroscopic, rheological, optical, and mechanical characterization techniques. The results showed that after 20 recycling steps of mechanical processing of polypropylene, the main degradation processes of polypropylene are chain scission of polymer chains and oxidation, which can be improved by the addition of a stabilizing additive. It was shown that a small amount of an additive significantly improves the properties of the recycled polypropylene up to the 20th reprocessing cycle. The use of an additive improves the rheological properties of the recycled melt, surface properties, and time-dependent mechanical properties of solid polypropylene since it was shown that the additive acts as a hardener and additionally crosslinks the recycled polymer chains.

The Impact of Reprocessing with a Quad Screw Extruder on the Degradation of Polypropylene

During mechanical recycling, polypropylene typically is reprocessed using a single- or twin-screw extruder. The degradation of polypropylene during this reprocessing reduces the polymer’s molecular weight and, consequently, limits the performance of the recycled resin. This work investigated the impact of a quad screw extruder (QSE), which has greater free volume, on the reprocessing of an impact copolymer polypropylene. To mimic the recycling process, the polypropylene was subjected to three processing cycles using a QSE and a comparable twin-screw extruder (TSE) operated at three screw speeds. The reprocessed materials were characterized for their rheological, morphological, and mechanical properties. For both extruders, increasing the number of reprocessing cycles and the screw speed resulted in higher melt flow indices, decreases in zero-shear viscosity, and shifting of the crossover points for the storage and loss moduli, which indicate reductions in the molecular weight and narrowing of the molecular weight distribution of the polypropylene. The QSE exhibited greater reductions in molecular weight compared to the TSE, probably due to the higher stresses associated with the three intermeshing points along its screws. Reprocessing caused a significant reductions in the Izod impact strength of the reprocessed polypropylene, which correlated with reductions in the particle size and particle size distribution of the dispersed rubbery phase in the polypropylene during reprocessing.