Maleic anhydride (MAH) grafting is widely employed to compatibilise polylactic acid (PLA) in fibre-reinforced composites; however, the influence of reactant addition sequence during melt processing varies widely across the literature, with no clear consensus on an optimal approach. In this study, the effect of reactant addition sequence on the graft yield of MAH onto PLA was investigated using dicumyl peroxide (DCP) as an initiator. Four loading protocols were examined in which the order of addition of PLA, DCP, and MAH was varied using approaches commonly reported in the literature, while all other processing conditions were held constant. A strong dependence of grafting yield on addition sequence was observed, with values ranging from 0.12% to 0.51%, corresponding to more than a four-fold variation under otherwise identical processing conditions. Simultaneous addition of PLA, DCP, and MAH produced the highest grafting yield, attributed to a more effective utilisation of peroxide-derived radicals. These results demonstrate that the reactant addition sequence is a critical processing variable governing MAH grafting efficiency and that simultaneous addition represents the most effective processing strategy under the conditions examined.

Maleic anhydride (MAH) grafting is widely employed to compatibilise polylactic acid (PLA) in fibre-reinforced composites; however, the influence of reactant addition sequence during melt processing varies widely across the literature, with no clear consensus on an optimal approach. In this study, the effect of reactant addition sequence on the graft yield of MAH onto PLA was investigated using dicumyl peroxide (DCP) as an initiator. Four loading protocols were examined in which the order of addition of PLA, DCP, and MAH was varied using approaches commonly reported in the literature, while all other processing conditions were held constant. A strong dependence of grafting yield on addition sequence was observed, with values ranging from 0.12% to 0.51%, corresponding to more than a four-fold variation under otherwise identical processing conditions. Simultaneous addition of PLA, DCP, and MAH produced the highest grafting yield, attributed to a more effective utilisation of peroxide-derived radicals. These results demonstrate that reactant addition sequence is a critical processing variable governing MAH grafting efficiency.