Characterization of Ecofriendly Polyethylene Fiber

from Plastic Bag Waste

Asril S. Soekoco a), Noerati b), Maya Komalasari, Kurniawan, Agus Hananto

Department of Textile Engineering & Textile Chemistry, Polytechnic of Textile Technology

Jl. Jakarta No 31, Bandung, West Java, Indonesia
a)
Corresponding author: asrilsenoaji@gmail.com,
b)
Co Author : noeratikemal@yahoo.com

Abstract. This paper presents the characterization of fiber morphology, fiber count and tenacity of polyethylene
fiber which is made from plastic bag waste. Recycling plastic bag waste into textile fiber has not developed yet.
Plastic bag waste was recycled into fiber by melt spinning using laboratory scale melt spinning equipment with
single orifice nozzle and plunger system. The basic principle of melt spinning is by melting materials and then
extruding it through small orifice of a spinning nozzle to form fibers. Diameter and cross section shape of
Recycled polyethylene fiber were obtained by using scanning electron microscope (SEM) instrumentation. Linear
density of the recycled fiber were analyzed by calculation using denier and dTex formulation and The mechanical
strength of the fibers was measured in accordance with the ASTM D 3379-75 standard. The cross section of
recycled fiber is circular taking the shape of orifice. Fiber count of 303.75 denier has 1.84 g/denier tenacity and
fiber count of 32.52 has 3.44 g/denier tenacity. This conditions is affected by the growth of polymer chain
alignment when take-up axial velocity become faster. Recycled polyethylene fiber has a great potential
application in non-apparel.

Keywords: melt spinning, polyethylene, recycled fiber, non-apparel textile

INTRODUCTION
Consumption of plastic bag tends to increase due to increment of convenience stores population. Most
of plastic bag is made from polyethylene polymer, low density polyethylene (LDPE) and high density
polyethylene (HDPE). Polyethylene polymer is non biodegradable material and it needs more time to
degrade. Efforts to handle plastic bag waste have been developed by thermal degradation technology to
produce fuel but it needs energy in the process and leads to air pollution [1]. Another effort to solve plastic
bag waste problem need to be developed, one of available alternatives is by recycling the waste into another
useful thing such as man made fiber. The demand of man made fiber shows positive increment, but
unfortunately recycling plastic bag waste into textile fiber has not developed yet. This research focus is to
produce and conduct characterization of recycled polyethylene from plastic bag waste.
Recycling is a process to breakdown the product into its raw materials and than use as material for
new products [2]. The plastic bag waste grouped as its color and thicknes prior to melt spinning process.
Plastic bag waste was recycled into fiber by melt spinning using laboratory scale melt spinning equipment
with single orifice nozzle and plunger system. The basic principle of melt spinning is by melting materials
and then extruding it through small orifice of a spinning nozzle to form fibers [3]. Fiber formed will be pulled
and winded by take-up roll. Fiber take-up velocity can influencing mechanical properties and diameter of the
fiber [4]. Fiber diameter and mechanical properties can be determined according to final product application.
 Figure 1. Melt Spinning Equipment

There are few methods to process thermoplastic polymer such as polyethylene, but considering
production cost and environment aspect, the best method is by melt spinning [5]. Most of polyester fiber
maker in Indonesia are also choosing this method than gel spinning. Melt spinning process also much more
environmental friendly since doesn’t produce side product as wet spinning.

EXPERIMENTAL

Making of Recycled polyethylene fiber

Plastic bag waste were cleaned to remove dirt and then inserted to the barrel after dried. Melt spinning
equipment with a single orifice of a spinning nozzle were arranged in processing temperature of 147 oC. The
melt spinning used 15 mm diameter barrel and 2 mm diameter orifice. Hold the process for 20 minutes to
reach uniform phase of material. The plunger velocity adjusted at 12 mm/minute to force melted polymer
pass through the orifice. Melted polymer solidified after had contacted with room air and then pulled by take-
up roll.

Figure 2. (a) Thinnest Diameter of Recycled Polyethylene Fibers

(b) Thicker Diameter of Recycled Polyethylene Fibers
 Recycled Fiber Morphology
Diameter and cross section shape of Recycled polyethylene fiber were obtained by using scanning
electron microscope (SEM) instrumentation. Linear density of the recycled fiber were analyzed by
calculation using denier and dTex formulation. Denier is unit to determine fiber weight in 9000 meters and
dTex is unit to determine fiber weight in 100 meters. Measured the length of recycled polyethylene fibers
specimens and then weighed using high precision scale. The recycled polyethylene fiber diameter was
directly proportional with dTex and denier value.

Recycled Fiber Tensile Strength Test

The mechanical strength of the fibers was measured in accordance with the ASTM standard (D 3379-
75) with Textechno-Favigraph and a gauge length of 0,5 cm. The number of test for each recycled
polyethylene fiber is 20 in order to reach high accuracy. This tensile strength test was performed in 12 mm/m
test speed. The tensile test result than divided with recycled polyethylene fiber linear density to obtain the
fiber tenacity.

(1)

RESULTS AND DISCUSSION

Cross Section and Linear Density

The cross section of recycled polyethylene fiber was almost circular taking the shape of orifice. This
fiber cross section built because of melted polymer spread by surface stress from take up motion. After
passed through the orifice, macromolecules of polyethylene will release their entropy and will be take form
like a ball, take up motion will generate draft and make the cross section almost circular [6]. The orifice in
this melt spinning equipment is replaceable in order to obtain flexibility to achieve various fiber cross section
and diameter. This experiment used 2 mm of orifice diameter, another orifice has 0,5 mm diameter and 5 mm
diameter. Fiber diameter can be arranged as its application. For apparel, commonly needs smaller fiber
diameter.

Figure 3.Cross Section of Recycled Polyethylene Fiber

 Diameter of recycled fiber was influenced by take up velocity and also the melted polymer
throughput. High take up velocity leaded to smaller fiber diameter but high amount of melted polymer
throughput leaded to bigger fiber diameter. Comparison of take up velocity against melted polymer
throughput known as draw ratio. Draw ratio value was inversely proportional to fiber diameter and linear
density. As the take-up speed is increased, the draw ratio increases and finer fibers are produced [7].

Table 1. Correlation of Draw Ratio and Linear Density of Recycled Polyethylene Fiber

No Draw Ratio Denier dTex

(%)

1 50 303.75 334.13

2 100 126.25 138.88

3 200 67.30 74.03

4 300 45.12 49.63

5 400 32.52 35.77

Recycled Fiber Tensile Strength

In textile terminology, fiber strength is known as tenacity with gram/denier as the common unit.
Various linear density of fiber has its own tenacity value even though it has same material and processing
temperature. Linear density of fiber has inversely proportional value with fiber tenacity, smaller linear
density of fiber leads to higher fiber tenacity.

Table 2. Correlation of Linear Density and Tenacity of Recycled Polyethylene Fiber

No Linear Density Tenacity

(denier) (g/denier)

1 303.75 1.84

2 126.25 2.18

3 67.30 2.86

4 45.12 3.07

5 32.52 3.44

This condition occurred because when producing smaller linear density, high take up velocity applied
and the draw ratio increased. Increment of draw ratio made aligned and increment of molecular chain
orientation, the molecular chains became more tight each others. Increment of molecular chain alignment
leads to hike of tenacity [8,9].
 crystalline

amorphou
s

Figure 4. (a) Molecular chain alignment in low draw ratio

(b) Molecular chain alignment in high draw ratio

This tenacity increment also influenced by increment of degree of crystallinity of the fiber. As the
spinning speed increases, crystallinity and molecular orientation of the fiber increase [10]. Percentage of
crystalline region were obtained using X-ray diffraction (XRD). Crystalline region influenced to ultimate
strength of recycled polyethylene fiber and amorphous region influenced to elongation of recycled
polyethylene fiber. Thinnest recycled polyethylene fiber (32,52 denier) has more crystalline region than
thickest recycled polyethylene fiber (305,75 denier). This X-ray diffraction result was directly proportional
with tensile strength test.

Thinnest recycled polyethylene fiber (32,52 denier) has 56 % crystalline region with 3,44 g/denier of
tenacity and thickest recycled polyethylene fiber (305,75 denier) has 32 % crystalline region with 1,84
g/denier of tenacity. Difractogram of Recycled Polyethylene Fiber can be seen at Fig.5.

Figure 5. Difractogram of Recycled Polyethylene Fiber

 CONCLUSION
Recycled polyethylene fiber from plastic bag waste has been made with laboratory scale melt spinning
equipment. The cross section of recycled fiber is circular taking the shape of orifice. Fiber diameter can be
arranged by changing the take-up axial velocity, higher take-up axial velocity leads to lower fiber count.
Higher take-up axial velocity influences to the increment of tensile strength of recycled fiber. Fiber count of
303.75 denier has 1.84 g/denier tenacity and fiber count of 32.52 has 3.44 g/denier tenacity. Thinnest
recycled polyethylene fiber (32,52 denier) has 56 % crystalline region and thickest recycled polyethylene
fiber (305,75 denier) has 32 % crystalline region.

ACKNOWLEGMENT
The authors would like to give appreciation and great thank to Pusdiklat Kementerian Perindustrian,
due to the funding of SPIRIT 2016 for this research.
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