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<p>The increasing demand for sustainable materials has intensified efforts to convert post-consumer plastic waste into high-performance composites. This study presents the development and optimization of eco-friendly wheat husk-reinforced polypropylene (WH-PP) composites using mechanically recycled ortho-grade PP waste. Wheat husk (WH) was incorporated at 10–30&#xa0;wt.% and particle sizes of 125–500&#xa0;μm. Mechanical tests revealed that the optimal formulation, i.e., 90&#xa0;wt.% PP and 10&#xa0;wt.% WH with 125&#xa0;μm particles exhibited superior tensile (47.4&#xa0;MPa), compressive (65.26&#xa0;MPa), and flexural strength (47.8&#xa0;MPa). Thermal analysis via thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC) confirmed enhanced stability and crystallinity at lower filler contents. Scanning electron microscopy (SEM) micrographs indicated improved interfacial adhesion with finer WH particles, while Fourier transform infrared spectroscopy (FTIR) spectra confirmed reduced degradation-related peaks. A multi-response optimization using the composite desirability function (CDF) validated this formulation as the most desirable. The resulting composite demonstrates potential for semi-structural applications such as assistive devices, lightweight automotive parts, and sustainable packaging. This work highlights the technical feasibility and environmental benefit of valorizing agricultural and plastic waste into high-performance bio composites.</p> Graphic Abstract <p></p>

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Eco-Friendly Composites from Polypropylene (PP) Waste: Development and Characterization of Wheat Husk-Reinforced PP Composite

  • 期刊论文

  • 发表日期：

    2026年4月5日

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  • Qazi Muhammad Usman Jan,
  • Tufail Habib,
  • Sahar Noor

摘要

The increasing demand for sustainable materials has intensified efforts to convert post-consumer plastic waste into high-performance composites. This study presents the development and optimization of eco-friendly wheat husk-reinforced polypropylene (WH-PP) composites using mechanically recycled ortho-grade PP waste. Wheat husk (WH) was incorporated at 10–30 wt.% and particle sizes of 125–500 μm. Mechanical tests revealed that the optimal formulation, i.e., 90 wt.% PP and 10 wt.% WH with 125 μm particles exhibited superior tensile (47.4 MPa), compressive (65.26 MPa), and flexural strength (47.8 MPa). Thermal analysis via thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC) confirmed enhanced stability and crystallinity at lower filler contents. Scanning electron microscopy (SEM) micrographs indicated improved interfacial adhesion with finer WH particles, while Fourier transform infrared spectroscopy (FTIR) spectra confirmed reduced degradation-related peaks. A multi-response optimization using the composite desirability function (CDF) validated this formulation as the most desirable. The resulting composite demonstrates potential for semi-structural applications such as assistive devices, lightweight automotive parts, and sustainable packaging. This work highlights the technical feasibility and environmental benefit of valorizing agricultural and plastic waste into high-performance bio composites.

Graphic Abstract