Advanced Plastic Waste Recycling—The Effect of Clay on the Morphological and Thermal Behavior of Recycled PET/PLA Sustainable Blends

Bio-based polymers such as poly(lactic acid), PLA, are facing increased use in everyday plastic packaging, imposing challenges in the recycling process of its counterpart polyester poly(ethylene terephthalate), PET. This work presents the exploration of the properties of PET/PLA blends with raw materials obtained from recycled plastics. Several blends were prepared, containing 50 to 90% PET. Moreover, multiscale nanocomposite blends were formed via melt mixing using different amounts and types of nanoclay in order to study their effect on the morphology, surface properties, and thermal stability of the blends. The materials were characterized by X-ray diffraction analysis (XRD), thermo-gravimetric analysis (TGA), scanning electron microscopy (SEM), atomic force microscopy (AFM), and differential scanning calorimetry (DSC). The nanoclay was found to exhibit a uniform dispersion in the polymer matrix, presenting mainly intercalated structures with some exfoliated at low loading and some agglomerates at high loading (i.e., 10%). The addition of nanoclay to PET/PLA matrices increased the roughness of the blends and improved their thermal stability. Thermal degradation of the blends occurs in two steps following those of the individual polymers. Contamination of rPET with rPLA results in materials having poor thermal stability relative to rPET, presenting the onset of thermal degradation at nearly 100 °C lower. Therefore, important information was obtained concerning the recyclability of mixed PET and PLA waste. The perspective is to study the properties and find potential applications of sustainable blends of recycled PET and PLA by also examining the effect of different clays in different loadings. Therefore, useful products could be produced from blends of waste polyester.