Investigating the Impact of Seasonal Input Stream Fluctuations on Post-Consumer High-Density Polyethylene Composition and Processing

The recycling of plastics collected from household waste to produce post-consumer recycled (PCR) materials is a critical step of sustainable waste management. However, the processing of PCR materials presents unique challenges, particularly in the context of seasonal input stream fluctuations and resulting PCR material composition variations. Within this paper, the influence of batch-to-batch fluctuations on the processing stability and product properties of high-density polyethylene (HDPE) PCR from the German municipal waste system is analysed. It examines how variations in batch composition affect key parameters such as processing data (injection pressure, torque), mechanical properties (tensile strength, E-modulus, impact strength), and product quality (gel formation, part dimensions, part weight). Therefore, six consecutive household HDPE PCR material batches are analysed regarding their composition, contaminations, and rheological characteristics through ashing, differential scanning calorimetry, high-temperature gel permeation chromatography, and high-pressure capillary rheometry. The batches are then processed using blown- and cast-film extrusion as well as injection moulding, and the resulting process stability and product quality are analysed. The results show a strong correlation between thermal properties, such as crystallisation enthalpy, molecular weight, polypropylene (PP) content, varying batch viscosities, and changes in processing data as well as the resulting product properties.