Assessment of property profile of post‐industrial polypropylene recyclates through a multivariable recycling process

Abstract This study provides key insights into the extrusion of a post‐industrial feedstock primarily composed of polypropylene (PP) and reveals its influence on the property profile of the recyclate. The objective of this study was to gain a fundamental understanding of complex process‐property relationships. Therefore, a two‐part experimental design was established. The first part aimed to analyze the feedstock variability by investigating key material properties of recyclates produced under constant processing conditions. The second part aimed to systematically evaluate the effect of the screw speed, filtration setup, and degassing setup on the properties of the recyclates. An industrial‐scale recycling extrusion line was used. The material evaluation included melt mass‐flow rate (MFR), ash content, oxidation induction temperature, tensile and impact properties, degassing performance, and residual volatile organic compounds (VOCs). Higher melt temperatures led to chain scission of the PP fraction, resulting in increased MFR and higher material stiffness. Additionally, a finer filtration positively contributed to the enhanced material stiffness. Furthermore, the mechanical properties were also influenced by the levels of inorganic fillers in the material composition of the feedstock. Finally, the filtration setup had a greater impact on degassing performance and residual VOC levels than the degassing setup and screw speed.