Optimization of the Mechanical Recycling of Phenolic Resins for Household Appliances

In light of the significant impact of climate change, it is imperative to identify effective solutions to reduce the environmental burdens of industrial production and to promote recycling strategies also for thermosetting polymers. In this work, the mechanical recycling of phenolic resins, obtained from industrial production scrap of plastic knobs for household appliances, was optimized. The feasibility of a partial substitution of virgin materials with recycled ones was investigated both at a laboratory and industrial scale. Finally, the environmental benefits arising from the use of recycled material were quantified through a life cycle assessment (LCA). The results of laboratory characterization demonstrated that the thermal properties of the phenolic resins were not influenced by the presence of recycled material, and the mechanical performances were not significantly impaired up to a recycled content of 30 wt%. The industrial production trials demonstrated the feasibility of replacing up to 15 wt% of virgin material without any influence on the aesthetical features of the produced components. Finally, LCA of industrially produced knobs highlighted a limited benefit of virgin material substitution in the case of novolac chromium-plated samples, while an overall environmental impact reduction of around 7-10% was detected in the case of resol-based materials.