In this study, various wood material sources were used for the manufacture of wood-polymer composites (WPC). The materials were categorised as virgin wood particles (VWP), reprocessed WPC particles (RWP) and recycled thermoset composite particles (RCP) and derived from two virgin wood sources, three-layer particleboards, medium-density fibreboards (MDF) boards, or two different wood/polypropylene composites. All produced wood-polypropylene compounds contained 60% wood material and were manufactured using a co-rotating extruder. Malleated polypropylene was used as a coupling agent. Specimens were injection moulded and subsequently tested for their physico-mechanical properties. To characterize particles before and after processing, dynamic image analysis (DIA) measurement were performed. Additionally, X-ray micro-computed tomography (XµCT) was used to characterize the internal structure of the composites and to verify the obtained particle’s characteristics. It was found that length and aspect ratio of particles were remarkably different before and after processing (loss in length of 15–70% and aspect ratio of 10–40%). Moreover, there were notably differences between the particle sources (RCP retained the highest length and aspect ratio values, followed by VWP and RWP). The results suggest that increased aspect ratios can indeed significantly improve mechanical properties (up to 300% increase in impact bending strength and 75% increase in tensile strength, comparing WPC based either on virgin spruce or MDF material). This phenomenon is suggested to be partially superimposed by improved dispersion of particles, which is expected due to lower variance and increased mechanical properties of RWP composites. However, no notable alterations were observed for composite density. Reprocessed WPC and, particularly, RCP material have proved to be an appealing raw material substitute for the manufacturing of wood–polymer composites.

In most countries, fibreboards are not recovered after utilization but burned for energy production. This study aims at recovering fibres from industrial fibreboards and reusing them as reinforcement elements in wood polymer composites (WPC). Recovered fibre (RF) material was generated by the thermo-hydrolytic disintegration of medium and high density fibreboards bonded with urea-formaldehyde resin. Various formulations of RF and polypropylene were used with or without the addition of the coupling agent to manufacture WPC using a co-rotating extruder. Test specimens were produced via injection moulding whereby those containing ‘virgin’ fibres served as a reference with respect to mechanical and physical properties. WPC formulations containing RF and ‘virgin’ fibres exhibited similar results, but composites containing RF exhibited improved mechanical and water-related properties, especially without coupling agent. The study indicates that recovered fibres are suitable to produce WPC with very similar physico-mechanical properties as those from ‘virgin’ fibres.