Sustainable PVC composites: life cycle assessment of resinated paper waste as a filler for reducing CO₂ emission

The disposal of industrial waste and the production of plastic are contributors to global CO2 emissions, highlighting the need for sustainable material alternatives. This study explores the development of polyvinyl chloride (PVC) matrix and resinated paper waste (RPW) fiber composites aiming to reduce environmental impact. RPW was characterized by using Fourier transform infrared spectroscopy (FTIR) and scanning electron microscopy (SEM) to analyze its chemical composition and microstructure. The composite was produced in five different formulations and evaluated for tensile strength, elongation, and fractographic properties. Life cycle assessment (LCA) was conducted using simulations to determine energy consumption and CO2 emissions. FTIR analysis confirmed the presence of polymer in RPW, which presents challenges for industrial recycling. Mechanical tests showed that RPW can be incorporated without significantly compromising tensile strength, while SEM revealed adequate fiber–polymer interaction up to 15 wt% RPW addition. LCA results demonstrated that RPW disposal accounts for 1.2% of CO2 emissions per ton of paper produced, further emphasizing its environmental impact. Under a simplified scaling scenario, assuming an annual global PVC production of 62 million tons and the incorporation of 5 wt% RPW, the potential CO₂ reduction was estimated at approximately 37,200 tons per year. This result suggests that RPW incorporation may represent a sustainable and scalable alternative for both PVC production and RPW management.