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In this study, the production of stereocomplex PLA formulations (sc-PLA) by compounding and subsequent injection moulding at different mould temperatures was investigated. Several selective nucleating agents were identified and compounded with different poly(L-lactide)/poly(D-lactide) (PLLA/PDLA) ratios on a co-rotating twin screw extruder. The effect of nucleating agents (NA) on the crystallisation behaviour of the compound was systematically investigated by DSC analysis. The crystallisation behaviour of NA-21 (aluminium complex of a phosphoric ester), also in combination with talc, under cooling rates of up to 70 K/min was analysed. The wide-angle X-ray diffraction (WAXD) results showed a complete stereocomplex (sc) crystal formation on all specimens containing NA-21 even at the highest cooling rates. The thermo-mechanical testing of sc-PLA shows a Young’s modulus of approx. 3 GPa, yield stress of 30–40 MPa, elongation of 1%, and a heat deflection temperature (HDT-B) up to 180 °C. Processing sc-PLA exclusively via the processing route of compounding and injection moulding will open new areas of application for PLA at higher temperatures.

Compounding is the final processing step for quality adjustment and control before recycled thermoplastic polymer material can be introduced into production processes. Motivated by the need for higher recyclate shares, the research question is which quality problems recycling compounders are encountered in practice, where they occur, and which mitigation options might be reasonable. Therefore, an online survey with 20 recycling compounders based in Germany was conducted asking about typical processing steps and processed materials, test procedures for quality assurance, quality problems, and possibilities for reducing quality problems. Results show that compounders mainly name impurities and contaminations of the input material as challenging and the reason for quality problems. The study shows that the problems are not dependent on the material input type. Quality problems occur along the entire secondary value chain, with companies manufacturing components themselves being particularly affected. The composition determination of the input materials helps to minimize quality problems.

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