Polypropylene (PP) is a highly sought-after synthetic polymer. Due to its properties, it has wide applications in a number of industries. One-dimensional molded materials (fibers and strands) are widely used in the textile and construction sectors. Concrete reinforcing using PP fiber is an intriguing use in construction. Fiber can be provided in two forms: fine fibers (microfiber) and extrudates (macrofiber). The macrofiber has a length of up to 60 mm and a thickness of up to 300 microns. The aim of the work was to obtain PP-based macrofibers from recycled polymer using the natural antioxidant tocopherol. The initial polymer is used to produce the fiber, whereas, in this work, it is proposed to use a secondary PP. Vitamin E, a natural antioxidant, was added to the system to stabilize the melts. It has been demonstrated that adding up to 0.5% Vitamin E reduces the heat degradation of the polymer and yields melts with the appropriate viscoelastic characteristics. Rheological data was used to determine the fiber’s formability window. Macrofibers were derived from melts with varying histories. Their structure was investigated using X-ray structural analysis and IR spectroscopy, and their mechanical characteristics were assessed.

In this study, a new approach to stabilizing polypropylene (PP) melts using the bio-based antioxidant propyl gallate (PG) is considered. Since PG is extensively used in the food and cosmetics fields and its low doses do not cause reactions in humans, producing PP melts with PG is an interesting approach. Furthermore, PG is already actively used in the processing of natural polymers, for example, in the NMMO process. It is shown that introducing up to 0.2 wt.% PG into the system is sufficient to significantly reduce the decrease in melt viscosity during repeated PP processing. After five processing cycles, the viscosity of systems with PG decreases by less than an order of magnitude, while for melts without the antioxidant the viscosity drops by almost three orders of magnitude to 10 Pa s. For melts with antioxidant additives, the crossover point position in the frequency dependences remains virtually unchanged, indicating the preservation of the system’s elastic properties. Macrofibers were spun from the resulting melts, which can then be used for concrete reinforcement. For the spun fibers with PG, the strength decreased to 68.1 MPa after five passes, whereas for the PP fibers, the values did not exceed 31 MPa. The structure and properties of the fibers were studied using X-ray diffraction and IR spectroscopy, and contact angles were determined.