Improving Fire Performances of PEAL: More Second-Life Options for Recycled Tetra Pak(®)

The purpose of this work was to evaluate and improve the flammability and combustion behavior of the polyethylene-based material obtained from the recycling of Tetra Pak(®) (PEAL) to widen its use to applications where these properties are required. Firstly, its thermal stability was investigated with thermogravimetric analysis, resulting in an enhancement in the main degradation step temperature (from 385 °C to 421 °C) due to the presence of the aluminum-flakes. Then, to improve the poor flammability (HB in UL-94 test) and combustion behavior (Fire Performance Index of 0.07) of the raw material, two flame retardant approaches were tested: an intumescent system made of ammonium polyphosphate and pentaerythritol, and magnesium hydroxide. In addition, the effectiveness of polyethylene as a charring agent was evaluated. Characterization was made with UL-94, cone calorimeter, and morphologic analysis. For all the materials tested, the temperature of the main weight loss step increased and the flammability rating improved (V2 for intumescent and V0 for magnesium hydroxide reached). Moreover, fire hazard decreased (Fire Performance Index of 0.15 and 0.55; Flame Retardancy Index of 2.6 and 10.0). Referring to the morphology, full compatibility was found in the PEAL–magnesium hydroxide compound, while PEAL-intumescent appeared as a heterogeneous system.