Systematic Characterization and Property Enhancement of Recycled PE Flexible Film Packaging

The production of plastic recyclates is becoming an increasingly feasible and common practice within the industry. Nevertheless, these materials are frequently downcycled for use in applications of reduced value. To bridge the gap between recyclate properties and end-use requirements in flexible packaging, this study investigates the systematic blending of three distinct post-consumer polyethylene (PE) flexible film packaging waste streams with virgin PE materials (low-density and linear low-density). A comprehensive characterization using melt mass-flow rate, oxidation onset temperature, transparency, tensile properties, and puncture properties was conducted on the modified recyclates. Additionally, three commercially available polyethylene-based recyclates and five commercial products containing these recyclates were investigated. The study employs a systematic approach to evaluate the properties of both lab-created and commercial recyclates, as well as those of commercially available flexible film packaging. In light of these findings, recommendations are put forth for the targeted applicability of the recyclates. Results show that key mechanical and optical properties improve with increasing virgin content, though in several cases, up to 80% recyclate content still met or exceeded property requirements for target applications. By enhancing the properties of the recyclate and enabling precise classification for specific applications, this research proposes optimized material formulations and targeted market applications, thereby facilitating the expansion of the scope and value of recycled plastics in the circular economy.