Upcycling of recycled polyethylene for rotomolding applications via dicumyl peroxide crosslinking

Abstract Polyethylene (PE), including high‐density polyethylene (HDPE) and low‐density polyethylene (LDPE), makes up a significant part of post‐consumer plastics in municipal solid waste, presenting challenges for traditional recycling methods due to a wide range of melt flow properties and poor interfacial adhesion between the different resin, which often leads to low quality products (downcycling). In this study, a method is proposed to modify the molecular structure of post‐consumer PE (rHDPE and rLDPE) and their blends by using a straightforward organic peroxide crosslinking technique with 1 phr of dicumyl peroxide (DCP). Different rHDPE/rLDPE blend weight ratios (0/100, 20/80, 40/60, 50/50, 60/40, 80/20, and 100/0) were prepared using a combination of co‐rotating twin‐screw extrusion and pulverization. The final parts were produced via rotomolding where both the forming and crosslinking processes occurred concurrently. Subsequently, the materials were characterized in terms of chemical, thermal, and mechanical properties. It was found that the tensile strength (228%), tensile modulus (345%), flexural strength (145%), and flexural modulus (251%) increased by crosslinking the 80% wt. rHDPE (x‐rHDPE). Conversely, the gel content increased by 17%, thermal resistance by 37.2%, and the impact strength by 93% with 80% wt. rLDPE (x‐rLDPE). It can be concluded that a balance between the properties occurs as the addition of DCP improved both the interfacial adhesion and melt properties of rHDPE/rLDPE blends. This innovative approach represents a simple and straightforward method to upcycle mixed plastics (PE) streams, especially for rotomolding applications. It also offers promising avenues for sustainable waste management and material reuse.