Theory/literature review

Polypropylene

A composite material is well known as a system of materials of consisting of two or more

materials which are mixed or bonded together on a macroscopic scale. A composite material is
generally composed of reinforcement embedded in a matrix (polymers, metals, etc.). The
reinforced material will improve the overall mechanical properties of the matrix while its holds
the reinforcement. PP is a thermoplastic polymer and can be made by polymerizing propylene
molecules, (Quazi T. H. Shubhra, April 2013).

Property Test method Homopolymer

Melt-flow index (MFI) a 3.0 0.7 0.2
b 500 (lb in-2) 4400 (lb in-2) 4200 (lb in-2)
Tensile strength
34 (MN/m2) 30 (MN/m2) 29 (MN/m2)
Elongation at break (%) b 350 115 175
- 190 000 (lb in-2) 170 000 (lb in-2) 160 000 (lb in-2)
Flexural modulus
1310 (MN/m2) 1170 (MN/m2) 1100 (MN/m2)
Brittleness I.CI. /ASTM +15 0 0
Temperature (oC) D746
Vicat softening point (oC) BS 2782 145-150 148 148
Rockwell hardness - 95 90 90
Impact strength (ft lb) - 10 25 34
Table 1. Some mechanical and thermal properties of commercial polypropylene

PP has the lowest density among commodity plastics which was made itself discovered and
strong popularity in the industry. It also has an excellent chemical resistance and can be
processed through many converting methods such as injection molding and extrusion. PP are
particularly suitable for items such as trays, tupperware, laundry detergent and ice-cream
packaging which is PP has major advantage related to the high temperature resistance that must
be sterilized (cleaned) for use in a clinical environment. PP also is a free-color material with
excellent mechanical properties which better than polyethylene (Plastic Properties of
Polypropylene (PP), 2011). According to Hisham A. Maddah, a linear polypropylene produces
plastics with high modulus and tensile strength, rigidity and excellent heat resistance. PP can be
made to have better durability by its ability to reinforcing and filling. Besides that, it also can be
improved to make moisture resistance and high strength properties and glass fibers produce very
good mechanical properties composites. Even though recycling of polymers causes depletion in
their optical properties, semi-crystalline isotactic polypropylene (iPP) showed excellent
mechanical properties and appropriate optical characteristics upon recycling (Maddah, 2016).

Injection Molding

Injection molding is a process in which molten polymer is forced under high pressure and
temperature into a mold cavity through an opening (sprue). According to INEOS Olefins &
Polymers USA, polypropylene can be molded in standard screw molding equipment without
alterations. Although pre-drying is not necessary under normal conditions, it may be required for
filled resins. The two most important variables available to the molder are cylinder temperature
and injection pressure (Polypropylene Processing Guide, March 2007).

Cylinder temperatures ranging from 400 570oF are the best to obtained the best results.
Cylinder temperatures should be 25-50F higher than the minimum temperature required to fill
the part, but not over 570F. A cylinder temperature profile is recommended with the hopper or
feed section being 30-50F lower than the nozzle. Improper cylinder temperatures can cause a
variety of problems. Problems such as flashing and burning can be occur because of too high of
a temperature. Shrink phenomena can be occur too such as sinking, warpage, shrinkage, and void
formation. Too low of a temperature can promote flow marks, weld lines, poor surfaces,
lamination, and short shots. Injection time also play important role as to achieve good portion of
the overall cycle. Injection time will influence in controlling warpage as compared to its major
role in control of shrinkage.
Apparatus

In waste plastics recycling process, waste plastics

crushing is one of the most important processes, the
volume of waste plastic is reduced, which is convenient
for subsequent processing. This machine basically used
to destroy the material's integrity to become small
pieces depend on the shear strength and the impact
strength.

Figure 2. Plastic Crusher Machine

Drying oven is used to remove moisture from the

crushed polypropylene plastics without cooking them.
This is to ensure there is no water element is included
during the injection molding process.

Figure 2. Laboratory Drying Oven

Temperature
control
button Hopper

Start
button

Mould

Figure 3. Vertical Injection Molding Machine

References
Maddah, H. A. (2016). Polypropylene as a Promising Plastic. American Journal of Polymer Science, 1-11.

Plastic Properties of Polypropylene (PP). (2011, August 12). Retrieved from Dynalon:
https://www.dynalon.com/PublicStore/

Polypropylene Processing Guide. (March 2007). INEOS Olefins & Polymers USA, 8.

Quazi T. H. Shubhra, A. A. (April 2013). Mechanical properties of polypropylene composites A review.

Journal of Thermoplastic Composite Materials, 365-366.