Optimization of an Industrial Recycling Line: The Effect of Processing Parameters on Mechanical Properties of Recycled Polyethylene (PE) Blends

This study concerns the optimization of an industrial recycling line; in other terms, this paper aims to find the optimal processing parameters that allow for a decrease in the loss of stress crack resistance (SCR) using a notched crack ligament stress (NCLS) test and an increase in the gain of the elongation at break, flexural modulus, and Izod impact strength of a polyethylene (PE) blend before and after recycling. The recycling line is composed mainly of a mono- and twin-screw extruder and a filtration system. Hence, the research question is as follows: How can we optimize the recycling process, without compromising the mechanical properties of recycled polyethylene (PE) blends? To answer the research question, Taguchi’s design of experiment and grey relational analysis (GRA) for multiobjective optimization was applied. Experiments were performed according to <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><msub><mrow><mi>L</mi></mrow><mrow><mn>16</mn></mrow></msub></mrow></semantics></math></inline-formula> standard orthogonal array based on five process parameters: mono-screw design, screw speed of the mono- and twin-screw extruder, melt pump pressure, and filter mesh size. Based on grey relational analysis (GRA), the optimal setting of process parameters was identified, and a barrier screw and a higher screw speed for both extruders were allowed to have optimal mechanical properties. Furthermore, the analysis of variance (ANOVA) indicated that the mono-screw design and screw speed of the mono- and twin-screw extruder significantly impact the mechanical properties of recycled polyethylene (PE) blends.