European legislation, particularly the Packaging and Packaging Waste Regulation (PPWR), is rapidly increasing the demand for high-quality recycled polypropylene (PP) in packaging applications. Achieving such qualities through mechanical recycling remains challenging due to the heterogeneity of post-consumer waste, while the role of intensified washing in the overall decontamination remains debated. This study evaluates the influence of additional sorting and washing intensity on material properties, product performance, and environmental impacts in mechanical recycling of Dutch post-consumer rigid PP. White, clear, and colored fractions were processed under cold and hot wash conditions, extruded, and converted into cups by injection molding and thermoforming. Sorting effectively reduced feedstock heterogeneity, while hot washing slightly improved oxidation stability and ductility. Cup testing showed that the investigated recyclates achieved 77-88 % of virgin polypropylene top load performance. Hot washing removed surface contamination but did not significantly reduce volatile organic compounds or migration levels. A Life cycle assessment (LCA) was performed in openLCA using Ecoinvent background data. The results showed that advanced mechanical recycling, despite higher energy and chemical demand, remained environmentally advantageous, achieving significantly lower climate change impacts compared to virgin PP. However, the recyclate substitution rate in final products was identified as the dominant driver of environmental benefits. Overall, maximizing substitution and sorting efficiency proved more effective for achieving sustainable, high-quality PP recycling than intensifying washing.

Recently, the European Commission announced their intention to restrict intentionally added microplastics to reduce the amount emitted by 0.5 million tons per year. Findings on microplastics indicate toxic behavior for biota, yet many mechanisms remain in the dark. Microplastics also pose a challenge in life cycle assessment as methods are actively being developed. Considering this recent decision, an anticipatory life cycle assessment was performed, comparing the impacts of natural grass pitches with artificial grass pitches using bio-based infill materials as well as polymeric ones made from recycled and virgin materials. The aim was to confirm if microplastics are in fact a considerable environmental hazard when compared to more traditional impacts. The microplastics’ impact was modeled after the MarILCA group’s work on the new midpoint of physical effects on biota. The results showed that the influence of the microplastics remains negligible when using the method provided. For most midpoint categories, the wood-based infill showed the best results, often closely tied with the infill made from recycled rubber from tires. A sensitivity analysis revealed that neither the physical effects on biota nor the greenhouse gas emissions from degradation in a marine environment are deciding factors when assessing the endpoint of ecosystem damage.