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Several composites based on recycled—virgin polypropylene, wood flour and organically modified montmorillonite (commonly called ‘nanoclay’) were prepared by melt compounding. This paper aims to evaluate the potential for the use of recycled polypropylene and underutilized wood flour as material for the development of wood–plastic composites, as well as reinforcement effect of organically modified montmorillonite on them. In order to improve the poor interfacial interaction between the hydrophilic wood flour and hydrophobic polypropylene matrix, as well as polypropylene–organically modified montmorillonite, maleic anhydride-grafted polypropylene was used as a compatibilizer. Some mechanical and physical properties were evaluated. Findings of this work show that both recycled and virgin polypropylene can be used in manufacture of wood–plastic composites and there is no significant difference in the properties of resulting nanocomposites. It was found that mechanical properties of polypropylene containing 40wt% wood flour reinforcement remain essentially unchanged when the virgin polypropylene in the matrix is replaced be recycled polypropylene. Morphologies of the nanocomposites were analyzed by scanning electron microscopy and X-ray diffraction, and the results showed increased d-spacing of clay layers indicating enhanced compatibility between polypropylene and clay and wood flour. Consequently, polypropylene recycled from postconsumer applications can be used in high-value nanocomposites without going the expense of separating out impurities from the polymer.

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