Optimization of mechanical properties of recycled plastic products via optimal processing parameters using the Taguchi method

The large amount of plastic products presently produced necessitates recycling and reuse of these non-biodegradable materials. However, the degradation in the mechanical properties of products made from recycled plastic is a major drawback that limits their use. This study aims to improve the mechanical properties of products made from recycled plastic by utilizing the Taguchi optimization method, instead of coupling the products with additives. By adopting L-9 Taguchi OA, products made from various compositions of virgin and recycled plastic are produced by injection moulding. Four controllable factors (i.e., melt temperature, packing pressure, injection time, and packing time), each at three levels, are tested to determine the optimal combination of factors and levels in the manufacturing process. By determining the optimal combination of factors and levels, the appropriate blending ratio of virgin and recycled plastic can be evaluated from the mechanical performance exhibited by the compound. The effects of the optimal processing parameters and the addition of recycled plastic in various compositions on the mechanical properties and melt flow index of the produced parts are also investigated. The results reveal that the product made of 25% recycled polypropylene (PP) and 75% virgin PP exhibits a better flexural modulus compared to the virgin form. The same product exhibits a 3.4% decrease in flexural strength. The degradation in mechanical properties of products produced from recycled plastic can be improved by optimizing the influence processing parameters during the manufacturing process. (C) 2011 Elsevier B.V. All rights reserved.