• MFA is used to predict flows of post-consumer flexible plastics (PCFP) via mechanical recycling. • The process yield of conventional and improved mechanical recycling is similar (64–66%). • Net recovery of transparent-monolayer PCFP reaches up to 93% in improved mechanical recycling. • Quality indicators indicate that the regranulates are of high purity. • MFA is used for decision support of new plastic waste recycling systems.

Within this research the effect of injection molding temperature on polypropylene (PP)/poly(ethylene terephthalate) (PET) blends and microfibrillar composites was investigated. Injection molding blends (IMBs) and microfibrillar composites (MFCs) of PP/PET have been prepared in a weight ratio 70/30. The samples were processed at three different injection molding temperatures (T_im) (210, 230, 280 °C) and subjected to extensive characterization. The observations from the fracture surfaces of MFCs showed that PET fibers can be achieved by three step processing. The results indicated that T_im has a big influence on morphology of IMBs and MFCs. With increasing the T_im, distinctive variations in particle and fiber diameters were noticed. The differences in mechanical performances were obtained by flexural and impact tests. Establishing relationships between the processing parameters, properties, and morphology of composites is of key importance for the valorization of MFC polymers.

Nanocomposites have attracted a great deal of interest during recent years. Much research has been conducted towards the incorporation of clay particles in a polypropylene matrix. However, the effect of extrusion reprocessing on the material properties has not been studied in depth. In this study, composites of polypropylene (PP) reinforced with organic modified montmorillonite (MMT) (4 wt%) and coupling agent were subjected to 15 extrusion cycles. The materials were characterized by melt flow index (MFI), plate-plate rheometry, tensile testing and impact measurements, differential scanning calorimetry (DSC), X-ray diffraction (XRD) and scanning electron microscopy (SEM). The results showed an improved intercalation of the MMT clay in the first few extrusions, thus improving the mechanical properties. Increasing the processing steps furthermore lead to a decrease in elastic modulus and impact strength, which was attributed to a reduction in matrix-filler interaction, most probably caused by organoclay degradation as shown by thermogravimetric analysis (TGA). The results of this study provide a useful insight in either the recycling of PP/MMT waste streams or the use of clay particles as a strengthening filler agent in the recycling process of different polymer waste streams.