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Blending polypropylene (PP) recyclates with virgin PP can create high-stiffness thermoforming trays. The best recyclate achieved 65% content while meeting melt flow rate and stiffness requirements.

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Area of Science:

  • Materials Science
  • Polymer Science
  • Recycling Technology

Background:

  • Polypropylene (PP) packaging waste presents diverse rheological and mechanical properties.
  • Post-consumer PP recyclates typically exhibit properties suitable for injection molding, not high-performance applications.
  • High-stiffness thermoforming trays require specific PP grades unattainable by standard recyclates.

Purpose of the Study:

  • To develop PP compounds from recyclates for high-stiffness thermoforming trays.
  • To investigate blending post-consumer PP recyclates with virgin PP.
  • To meet specific rheological and mechanical property demands for packaging applications.

Main Methods:

  • Acquired three commercial PP post-consumer recyclates.
  • Compounded recyclates with a virgin PP grade at varying ratios.
  • Adjusted blending ratios to achieve a target melt mass-flow rate (MFR) of 2-4 g/10 min.

Main Results:

  • PP recyclate compounds showed a clear correlation between recyclate content and performance.
  • The final properties were dependent on the initial quality of the recyclate.
  • The optimal recyclate allowed up to 65% content while meeting MFR and tensile stiffness (>1500 MPa) targets.

Conclusions:

  • Blending intermediate-performance PP recyclates with virgin PP is feasible for demanding applications.
  • Careful selection of recyclate source and blending ratio is crucial for achieving desired properties.
  • This approach enhances the value and application scope of PP recyclates in packaging.