An Approach Toward Achieving Greener Composites by Valorization of Waste and Other Underutilized Polymeric Materials

Abstract This study focuses on developing sustainable polymer composites by utilizing waste and underutilized materials as an alternative to virgin plastics. Recycling and reusing waste plastics can reduce carbon footprint and material costs, but limitations such as insufficient infrastructure and lack of public awareness in waste segregation hinder effective recycling. To address this, virgin HDPE and PP were partially replaced with waste plastics, while thermoplastic starch (TPS) was incorporated to form a polymer matrix in a 20:30:50 ratio. Waste BF was employed as reinforcement, and waste EG served as a heat stabilizer. Compatibilizers such as epoxidized soybean oil (ESO), polyethylene‐co‐glycidyl methacrylate (PE‐co‐GMA), or their combinations were used to enhance composite performance. The composites were thoroughly characterized using FTIR, SEM, TGA, tensile testing, chemical resistance, and LOI studies. Results revealed that PE‐co‐GMA‐based composites exhibited superior mechanical and thermal properties compared to ESO‐based ones, while blends of both compatibilizers showed intermediate behaviour. An optimum ESO‐to‐PE‐co‐GMA ratio of 13:2 offered enhanced moldability, improved mixing, reduced synthetic compatibilizer usage, and overall property enhancement. These findings demonstrate that composites based on renewable and waste‐derived materials can be engineered with desirable performance, offering a viable pathway toward sustainable plastic waste management and reduced dependence on virgin polymers.