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<p>This study examines the development of high-impact resistant (HIR) boards manufactured from multi-waste hybrid composites integrating waste plastics (HDPE, PET, PP), agro-industrial residues (rice husk, sawdust, palm kernel shells), and mixed recyclables (waste tires, broken glass/ceramics, kaolin). Although binary plastic–filler systems are widely studied, fewer than 5% of publications address genuine multi-component formulations that reflect real-world heterogeneous waste streams. Key findings reveal that optimised hybrid boards can achieve impact strengths of 20–35&#xa0;kJ/m², flexural strengths &gt; 30–40&#xa0;MPa, water absorption &lt; 8%, and 40–60% lower embodied carbon than conventional MDF, provided interfacial compatibility is resolved through compatibilisers, surface pretreatments, or advanced processing. The principal research gap remains the absence of reproducible, industrially scalable formulation pathways for simultaneous incorporation of four or more waste categories. Prioritised recommendations include multi-factor design-of-experiments coupled with machine-learning prediction, adoption of bio-based coupling agents and hybrid extrusion–microwave technologies, and policy frameworks supporting regional waste-to-value hubs. Successful implementation could enable HIR multi-waste boards to achieve substantial market growth, with potential to capture up to 15–20% of the global particleboard market by 2030 under optimistic adoption scenarios, diverting an estimated 25–35 Mt/year of mixed wastes and reducing CO₂e emissions by 50–70 Mt/year. These projections are based on current waste generation rates, projected circular economy policy targets, and conservative scaling from existing pilot capacities (Pudhupalayam Muthukutti et al., 2025; Okafor et al., 2025; Kapoor &amp; Rafatullah, 2025). Such outcomes would also support the creation of hundreds of thousands of circular-economy jobs while delivering technically superior, cost-competitive construction panels.</p>

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Optimizing Multi-Waste Hybrid Composites From Waste Plastics, Agro-wastes and Mixed Recyclables for High-Impact Resistant Boards: A Formulation Pathways and Scale-up Challenges

  • 期刊论文

  • 发表日期：

    2026年7月6日

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  • Sunday Uzochukwu John,
  • Chioma Mary John,
  • Calista Chimogo Ejiofor,
  • Poycarp Ikechukwu Nwabuokei,
  • JoyAnn Nwamaka Aningo

摘要

This study examines the development of high-impact resistant (HIR) boards manufactured from multi-waste hybrid composites integrating waste plastics (HDPE, PET, PP), agro-industrial residues (rice husk, sawdust, palm kernel shells), and mixed recyclables (waste tires, broken glass/ceramics, kaolin). Although binary plastic–filler systems are widely studied, fewer than 5% of publications address genuine multi-component formulations that reflect real-world heterogeneous waste streams. Key findings reveal that optimised hybrid boards can achieve impact strengths of 20–35 kJ/m², flexural strengths > 30–40 MPa, water absorption < 8%, and 40–60% lower embodied carbon than conventional MDF, provided interfacial compatibility is resolved through compatibilisers, surface pretreatments, or advanced processing. The principal research gap remains the absence of reproducible, industrially scalable formulation pathways for simultaneous incorporation of four or more waste categories. Prioritised recommendations include multi-factor design-of-experiments coupled with machine-learning prediction, adoption of bio-based coupling agents and hybrid extrusion–microwave technologies, and policy frameworks supporting regional waste-to-value hubs. Successful implementation could enable HIR multi-waste boards to achieve substantial market growth, with potential to capture up to 15–20% of the global particleboard market by 2030 under optimistic adoption scenarios, diverting an estimated 25–35 Mt/year of mixed wastes and reducing CO₂e emissions by 50–70 Mt/year. These projections are based on current waste generation rates, projected circular economy policy targets, and conservative scaling from existing pilot capacities (Pudhupalayam Muthukutti et al., 2025; Okafor et al., 2025; Kapoor & Rafatullah, 2025). Such outcomes would also support the creation of hundreds of thousands of circular-economy jobs while delivering technically superior, cost-competitive construction panels.