Effect of toughening agent and flame‐retardant additives on the recycled polypropylene/oil palm empty fruit bunch laminated composites

Abstract The increasing awareness of the environmental problems caused by the use of plastics has led to a demand for sustainable materials. The concept of turning waste into wealth has been considered in the study where the waste materials are value‐added into new composite materials that are recyclable, durable, and fire‐resistant. This effort aims to meet global environmental goals and the demand for high‐performance and sustainable building materials. The purpose of this current study is to develop laminated composites based on the combination of recycled plastic and oil palm empty fruit bunch (OPEFB). The addition of various loading of ammonium polyphosphate (APP) and 6 wt% of ethylene vinyl acetate (EVA) in the formulation was considered to enhance the performance of the composite laminates. The rPP and additives were compounded using a two‐roll mill. Then the rPP sheet and OPEFB were laminated using compression molding techniques. Results showed that rPP with addition of 30 wt% APP and 6 wt% EVA exhibited the highest thermal stability and the lowest melt flow index (MFI) value compared to other samples. Composites with 20 wt% APP and 6 wt% EVA showed 56% increase in flexural properties and 33% increase in impact strength compared to that of rPP/OPEFB composite sample without EVA. Addition of 30 wt% in recycled PP and OPEFB demonstrated self‐extinguished properties when exposed to fire compared to other samples. These findings indicated that rPP/OPEFB laminated composites with the addition of APP and EVA have a potential to be used in applications that require good strength and fire performance. The use of rPP/OPEFB composites with addition of APP and EVA has a potential to reduce virgin plastic consumption and agriculture material waste and establishing an environmentally friendly material for construction sector. Highlights Additives included in recycled PP enhance its thermal stability and reduce MFI. Recycled PP with OPEFB composite self‐extinguished at 30 wt% APP. The highest flexural strength is shown by composite laminates with 20 wt% APP and 6 wt% EVA. rPP/OPEFB laminates are ideal for building materials.