Hybrid artificial rattan from upcycled multi-layered packaging waste and natural fibers: Toward sustainable material innovation

This study investigates the feasibility of producing artificial rattan from multilayer plastic packaging waste from beverage cartons, combined with natural fibers, as a sustainable alternative to natural rattan. Beverage cartons consist of cardboard and a polyethylene film/aluminum foil layer known as “PolyAl,” which is difficult to degrade and recycle. To valorize this waste, PolyAl was blended with recycled linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), and polypropylene (PP) at mixing ratios of 0–90 wt%, then compounded using a twin-screw extruder and injection molding. The optimal recycled polymer blend was subsequently reinforced with bamboo particles at 0, 5, 10, and 15 wt%. Polypropylene-graft-maleic anhydride (PP-g-MA) was also added at 0, 3, 5, and 7 wt% to improve interfacial bonding between the reinforcement and matrix. Mechanical performance was evaluated by tensile, flexural, and Izod impact tests, and the results were analyzed using analysis of variance (ANOVA), confirming significant effects of material composition on mechanical properties (p < 0.05). The optimal formulation was a 30:70 (PolyAl:PP) blend containing 5 wt% bamboo particles and 3 wt% PP-g-MA, which achieved a tensile strength of 19.60 MPa, tensile modulus of 327.78 MPa, flexural strength of 28.12 MPa, flexural modulus of 543.08 ± 31.49 MPa, and impact strength of 100.93 J/m.