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Industrial-Scale Injection Moulding Validation of Recycled Fiber-Reinforced Polypropylene: Processability and Manufacturing Feasibility.

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Title: Industrial-Scale Injection Moulding Validation of Recycled Fiber-Reinforced Polypropylene: Processability and Manufacturing Feasibility.
Authors: Picazo Camilo, Elena1 (AUTHOR) epc@ecocastulum.com, Carrillo Beltrán, Raúl1,2 (AUTHOR), Perea Toledo, Griselda Elisabeth1,3 (AUTHOR), Corpas Iglesias, Francisco Antonio1,2,4 (AUTHOR), Bogataj, Vesna Žepič1,3 (AUTHOR), Kotnik, Simon2,4 (AUTHOR), Iglesias Godino, Francisco Javier2,3 (AUTHOR)
Source: Materials (1996-1944). Jun2026, Vol. 19 Issue 11, p2314. 18p.
Subjects: Injection molding, Polypropylene, Process capability, Cellulose fibers, Composite materials, Mass production
Geographic Terms: Spain
Abstract: Highlights: Industrial validation of recycled PP reinforced with natural fibers. Robust injection moulding confirmed across multiple industrial sites. No equipment modifications required under standard production conditions. Industrial-scale processability was successfully demonstrated under real manufacturing conditions. Suitable for implementation in real industrial manufacturing environments. This study evaluates the industrial-scale feasibility of injection moulding of a recycled polypropylene composite reinforced with recycled fibers derived from an industrial waste stream. Although previous laboratory-scale research has demonstrated the potential of natural fiber-reinforced thermoplastics, their large-scale industrial implementation remains limited due to uncertainties related to processability, reproducibility, and manufacturing robustness. In this work, the composite material is validated through injection moulding trials carried out in four independent industrial companies located in Andalusia (Spain) and three industrial case studies across different industrial sectors in Slovenia, operating under real production conditions. The extrusion process was characterized in terms of process stability, confirming continuous operation with automated dosing and stable material flow without interruptions under industrial conditions. Injection processing parameters, cycle stability, part quality, and defect formations are also considered important when assessing the manufacturing feasibility. The multi-site validation approach enables the evaluation of reproducibility across different injection moulding systems and mould geometries, providing critical insights into the scalability and technological readiness level of recycled natural fiber-reinforced polypropylene composites. Although direct energy consumption measurements were not systematically recorded, the observed processing stability and cycle repeatability indicate a consistent and energy-efficient operation under industrial processing conditions. The results contribute to bridging the gap between laboratory-scale material development and real industrial implementation. [ABSTRACT FROM AUTHOR]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Industrial-Scale Injection Moulding Validation of Recycled Fiber-Reinforced Polypropylene: Processability and Manufacturing Feasibility.
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  Data: <searchLink fieldCode="DE" term="%22Injection+molding%22">Injection molding</searchLink><br /><searchLink fieldCode="DE" term="%22Polypropylene%22">Polypropylene</searchLink><br /><searchLink fieldCode="DE" term="%22Process+capability%22">Process capability</searchLink><br /><searchLink fieldCode="DE" term="%22Cellulose+fibers%22">Cellulose fibers</searchLink><br /><searchLink fieldCode="DE" term="%22Composite+materials%22">Composite materials</searchLink><br /><searchLink fieldCode="DE" term="%22Mass+production%22">Mass production</searchLink>
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  Data: Highlights: Industrial validation of recycled PP reinforced with natural fibers. Robust injection moulding confirmed across multiple industrial sites. No equipment modifications required under standard production conditions. Industrial-scale processability was successfully demonstrated under real manufacturing conditions. Suitable for implementation in real industrial manufacturing environments. This study evaluates the industrial-scale feasibility of injection moulding of a recycled polypropylene composite reinforced with recycled fibers derived from an industrial waste stream. Although previous laboratory-scale research has demonstrated the potential of natural fiber-reinforced thermoplastics, their large-scale industrial implementation remains limited due to uncertainties related to processability, reproducibility, and manufacturing robustness. In this work, the composite material is validated through injection moulding trials carried out in four independent industrial companies located in Andalusia (Spain) and three industrial case studies across different industrial sectors in Slovenia, operating under real production conditions. The extrusion process was characterized in terms of process stability, confirming continuous operation with automated dosing and stable material flow without interruptions under industrial conditions. Injection processing parameters, cycle stability, part quality, and defect formations are also considered important when assessing the manufacturing feasibility. The multi-site validation approach enables the evaluation of reproducibility across different injection moulding systems and mould geometries, providing critical insights into the scalability and technological readiness level of recycled natural fiber-reinforced polypropylene composites. Although direct energy consumption measurements were not systematically recorded, the observed processing stability and cycle repeatability indicate a consistent and energy-efficient operation under industrial processing conditions. The results contribute to bridging the gap between laboratory-scale material development and real industrial implementation. [ABSTRACT FROM AUTHOR]
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  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.3390/ma19112314
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        Text: English
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        PageCount: 18
        StartPage: 2314
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      – SubjectFull: Injection molding
        Type: general
      – SubjectFull: Polypropylene
        Type: general
      – SubjectFull: Process capability
        Type: general
      – SubjectFull: Cellulose fibers
        Type: general
      – SubjectFull: Composite materials
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      – SubjectFull: Mass production
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      – SubjectFull: Spain
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      – TitleFull: Industrial-Scale Injection Moulding Validation of Recycled Fiber-Reinforced Polypropylene: Processability and Manufacturing Feasibility.
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            – D: 01
              M: 06
              Text: Jun2026
              Type: published
              Y: 2026
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