Industrial approach to circularity of polymer composites: Processing,characterization,mechanical testing,and wear regression

Cotton, polyester, and polyethylene terephthalate are the most common types of polymers that produce huge wastes. The circularity of these post-consumer (PC) waste faces operational problems during processing. In this innovative research, the relationship between circularity, surface characterization, mechanical and tribological testing of fiber reinforced (cotton, polyester), and particulate (polyethylene terephthalate) composites is explored for industrial pilot production. Cutting model can control the size of fibers during grinding. The fiber reinforced composites (FRCs) with 10% (by weight) fiber loadings are found as operational candidates for structural, automotive, and medical applications due to suitable tensile strength (26–29 MPa), percentage of extension (10%) and abrasive wear (3 × 10⁻⁶ mm³/Nm). An increase in fiber content produces micro-defects like asperities, rough areas, voids, cracks, and pits in recycled composites. Therefore, the particulate and FRCs with 40% (by weight) fiber loadings become hard and brittle. However, these composites (especially with 40% wt. fiber loadings) exhibit reasonable elastic modulus (1526–2751 MPa) and abrasive wear (6.5 × 10⁻⁶ mm³/Nm). The ductile to brittle transition effect has appeared in all composites (with 30% wt. fiber content) due to continuous fiber addition, micro-defects creation and dual phase presence. In conclusion, natural and synthetic PC wastes can be utilized for sustainable processing of commercial polymer composites. Moreover, injection molding, polymer characterization, tensile testing, abrasion evaluation, and regression analysis can be introduced for the transformation of open-loop into closed-loop manufacturing.