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<p>Expanded polystyrene (EPS or “thermocol”) is a widespread single-use polymer that accumulates in landfills and informal dumping sites, particularly in rural regions where recycling infrastructure is limited. This study presents a low-cost and practical method to convert post-consumer EPS into a functional adhesive by dissolving shredded EPS in toluene and incorporating a small fraction of epoxy resin and hardener. This simple approach offers a decentralized route for transforming plastic waste into a valuable material suitable for small-scale applications. The adhesive was formulated by dissolving EPS in toluene at a 1:3.33 (w/v) ratio, followed by adding epoxy resin and hardener at 1:1 (w/w), each representing 14% of the EPS mass. The formulation was evaluated through moisture content, pH, density, solid content, viscosity, FTIR analysis, thermal behavior, and mechanical testing. The adhesive exhibited a viscosity of 617 mPa s, solid content of 95.37%, moisture content of 2.74%, and a pH of 7.5–8.0, with a drying time of 1–5&#xa0;h. Bonding tests showed strong adhesion, with breaking forces of 50.6&#xa0;kg for wood–wood and 49.7&#xa0;kg for metal–metal joints. Thermogravimetric analysis indicated primary decomposition at 330–400&#xa0;°C and secondary degradation above 480&#xa0;°C, leaving 36.6% char, while FTIR confirmed characteristic aromatic and epoxy-related functional groups. The novelty of this work lies in developing an easy, low-infrastructure process combined with cost estimation (~ Rs. 50–60 per liter) and comparison with commercial adhesives. The study demonstrates an affordable, scalable, and environmentally relevant method for converting EPS waste into a multi-purpose adhesive suitable for rural and resource-constrained regions.</p> Graphical abstract

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Formation of a multifunctional adhesive from waste thermocol: an affordable option for rural uses

  • 期刊论文

  • 发表日期：

    2026年5月18日

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  • Neesha Sharma,
  • Kavita Kulkarni,
  • Vikas Choudhary,
  • Prashant Tayade

摘要

Expanded polystyrene (EPS or “thermocol”) is a widespread single-use polymer that accumulates in landfills and informal dumping sites, particularly in rural regions where recycling infrastructure is limited. This study presents a low-cost and practical method to convert post-consumer EPS into a functional adhesive by dissolving shredded EPS in toluene and incorporating a small fraction of epoxy resin and hardener. This simple approach offers a decentralized route for transforming plastic waste into a valuable material suitable for small-scale applications. The adhesive was formulated by dissolving EPS in toluene at a 1:3.33 (w/v) ratio, followed by adding epoxy resin and hardener at 1:1 (w/w), each representing 14% of the EPS mass. The formulation was evaluated through moisture content, pH, density, solid content, viscosity, FTIR analysis, thermal behavior, and mechanical testing. The adhesive exhibited a viscosity of 617 mPa s, solid content of 95.37%, moisture content of 2.74%, and a pH of 7.5–8.0, with a drying time of 1–5 h. Bonding tests showed strong adhesion, with breaking forces of 50.6 kg for wood–wood and 49.7 kg for metal–metal joints. Thermogravimetric analysis indicated primary decomposition at 330–400 °C and secondary degradation above 480 °C, leaving 36.6% char, while FTIR confirmed characteristic aromatic and epoxy-related functional groups. The novelty of this work lies in developing an easy, low-infrastructure process combined with cost estimation (~ Rs. 50–60 per liter) and comparison with commercial adhesives. The study demonstrates an affordable, scalable, and environmentally relevant method for converting EPS waste into a multi-purpose adhesive suitable for rural and resource-constrained regions.

Graphical abstract