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Journal of Polymer & Composites Original Research

Development of IoT-Enabled Circular-Economy Polymer Composites from Recycled Plastics and Agricultural Waste Fibers

  1. S. Lalitha Department of Computer Science & Engineering (Artificial Intelligence and Machine Learning), Vel Tech Rangarajan Dr. Sagunthala R& D Institute of Science and Technology, Avadi, Chennai
  2. Abhishek Bhattacherjee Department of Computer Science & Engineering, MM Engineering College, Maharishi Markandeshwar (Deemed to be University), Mullana, Ambala
  3. Rashid Hashmi Sharda School of Media Film & Entertainment, Sharda University
  4. Puvvada Nagesh Department of Computer Science and Engineering, Koneru Lakshmaiah Education Foundation, Vaddeswaram, Guntur District
  5. Rohini Goel Department of Computer Science & Engineering, Maharishi Markandeshwar Engineering College, Maharishi Markandeshwar (Deemed to be University), Mullana, Ambala
  6. Vandana Ahuja Department of Computer Science & Engineering, MM Engineering College, Maharishi Markandeshwar (Deemed to be University), Mullana, Ambala

Abstract

Circular polymer composites can help to decrease virgin resin consumption and provide value from agricultural waste, but there are still challenges with recycled-feedstock variability and poor fiber–matrix interfaces to achieve consistent performance. In this study, a circular composite system based on recycled polypropylene (rPP), recycled high-density polyethylene (rHDPE), bagasse fiber and rice-husk fiber was developed with the use of IoT technology. The polymer type, fiber type, reinforcement level (5, 10 and 15 wt.%) and compatibilization were investigated using a factorial design. The composite batches were melt compounded and the tensile, flexural, impact, thermal, rheological, morphological and water-absorption behavior of the compounded materials were characterized. Batch-level IoT data included temperature, pressure, screw speed, power consumption and processing stability, which was used for process–structure–property analysis and multi-response optimization. The highest tensile strength, tensile modulus and heat-deflection temperature of 33.10 MPa, 1698 MPa and 83.66 °C, respectively, were obtained for compatibilized rPP containing 10 wt.% bagasse, which resulted in the best overall balance. These values were 20.9%, 32.3% and 11.4 °C higher than neat rPP, respectively. Increased stiffness and thermal resistance were observed with higher loading (15 wt.%) but tensile efficiency, impact tolerance, moisture resistance and processability decreased. Compatibilization also lowered void content and water uptake. IoT-derived pressure variability and specific energy also showed clear associations with durability and thermal response across evaluated formulations. The integrated framework links recycled-material provenance, processing history, and composite performance, supporting traceable formulation selection for circular polymer manufacturing.

Keywords

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