Recycling of Polypropylene Medical Mask Waste to Shoe Fabric: Fabrication and

Characterization

ABSTRACT
In the last three years, polypropylene (PP) has been used to produce medical masks to protect the public
from the spread of viruses and bacteria Coronavirus Disease (COVID-19). However, many medical masks
were improperly disposed of and caused environmental pollution. This research aimed to recycle PP from
used masks using the melt-spinning method. The melt-spinning method involved heating the used medical
mask PP to a liquid state at temperatures procces 215˚C-225˚C, and then drawing it through a mold or small
hole to form fibers or yarn with variations ranging from 10% wt PP to 70% wt PP. The process involved
melting the polymer and forming fibers or yarn. Yarn variations were produced with different mask waste
percentages, mixed with virgin PP and cotton yarn for shoe fabric. The fabric produced was tested for yarn
count and tensile strength. Testing showed the successful results of the plain-woven fabric meeting
standards, such as tensile strength, tear strength, and contact angle. This study successfully produced a
plain-woven fabric with a composition of 10-20%wt of PP mask waste that met the Indonesian National
Standard 08-1793-1990. This approach reduces mask waste and enhances sustainability by creating
reusable products, contributing to environmental impact reduction and sustainable waste management.
Keyword: Medical Mask, Melt-Spinning Method, Polypropylene, Recycling, Shoe Fabric, Waste Processing

1. INTRODUCTION provide protection against moisture and water,

It has been more than two years since the
onset of the Coronavirus Disease 2019
(COVID-19) caused by severe acute respiratory
syndrome coronavirus-2 (SARS-CoV-2) [1, 2]
can be transmitted through respiratory
infections (person to person) and can be via
aerosols [3-5]. To prevent the spread of COVID-
19 via airborne aerosols, the World Health
Organization (WHO) proposes the use of
medical masks [4, 6]. However, the negative
impact arising from using medical masks is the
increase in medical mask waste. Medical waste
has a bad influence on public health, as well as
the environment [7]. One effort that can be
made to reduce problems arising from medical
waste is to recycle medical mask waste into
useful commercial products[8].
The main material for medical masks is
Polypropylene. Polypropylene is the most used
thermoplastics with mechanical properties of
high-water resistance, toughness, stress, tear,
acceptable elasticity limits, not easily broken,
good heat, easy to shape, flexible, easy to
color, and very difficult to be degraded by
nature [9, 10]. Several studies have been
conducted to recycle the waste of
polypropylene. For instance, recycled
polypropylene has been employed in alternative
fuel production [11], Medical packaging
applications [12], and oil/water separation [13].
Although there have been many journals
discussing the use of PP waste in various
products, no paper has discussed the use of PP
waste as a basic material for making shoe
fabrics. Polypropylene is a material that is very
light, even lighter than polyester and nylon, and
resistant to water, so polypropylene fabrics can
which can damage the shoes. With these
advantages, polypropylene is a popular choice
in the manufacture of shoe fabrics, especially
for shoes used in wet conditions or for outdoor
activities.
In general, PP waste can be recycled in several
ways, namely injection, extrusion, and melt
spinning[14, 15]. The melting spinning method
is the commonly selected manufacturing
process for making synthetic fibers from
polymeric materials by melting the material and
feeding it into a mold at high speed [16]. In the
melting spinning process, the polymer chains
will undergo creation and form of oriented
crystal lamella structures following the strain-
induced crystallization process [17]. To
overcome this, it is necessary to manage and
purify PP by combining recycled PP from
medical mask waste and pure PP. This PP
blending process can produce tenacity yarn,
reduce contamination, reduce PP particle size
variability, and improve fiber color clarity [18].
The yarn produced from this mixture will act as
the weft yarn in the fabric being made, while the
warp yarn which is an ordinary cotton yarn in
the manufacture of cotton-based shoes. The
yarn is then woven into fabrics to form
polypropylene fabrics. The produced fabrics are
then weaved and cut according to the shoe
pattern.
The process parameters used in the melt
spinning method are the influence of
temperature and speed in the process of
spinning into yarn. The temperature required for
spinning PP is usually in the range of 220-
280oC. If the temperature is too high, it may
cause the PP to melt or catch fire. In addition,
speed, pressure, and tension factors must also
be controlled during spinning to produce high-
quality PP yarn[17]. The author collaborated
with a recycling company that produced PP
pellets to utilize the PP waste as a raw material
in making yarn onto mixing with PP from
medical masks, with the aim of reducing
environmental impact and production costs.
This collaboration was also expected to open
opportunities for cooperation between
academia and industry in maintaining
environmental sustainability and developing
environmentally friendly technologies.
2. MATERIAL AND METHODOLOGY
In this study, pellets of polypropylene waste
were obtained from Kitakaya Inc. Indonesia,
which is a company that specializes in the
recycling of plastic materials, in various sizes
that are less than 2 cm, as shown in Fig 1.
Fig. 1 Recycling Polypropylene Virgin
Making Yarn Using Extrusion by Blending
Polypropylene Medical Mask Waste and
Polypropylene Injection Grade
The yarn was made by mixing medical mask
waste PP with injection-grade PP. The variation
used was 10-70% wt PP medical mask waste.
The ASTM standard for the use of recycled yarn
from medical mask waste PP and injection
grade PP in the manufacture of fabrics was
ASTM D6968-20. The process was carried out
by heating the extruder at a temperature of
120°C. The screw speed used in this study was
3 ± 0.2 rpm. Next was the purging process to
ensure that there was no residual material from
the previous process. The polymer would then
exit through the nozzle to form the yarn. The
yarn was then pulled using a puller and
wrapped around the spool. The puller speed
used in this study was 5 ± 0.2 rpm.
Making Yarn Using Melt-spinning Screw
System by Blending Polypropylene Medical
Mask Waste with Polypropylene Yarn Grade
Polypropylene masks waste had a cotton-like
shape that made it difficult to process for melt
flow rate and spinning tests. To overcome this,
the waste was transformed into pellets using a
pelletizer that included an extrusion machine
and chopper, following the ASTM D7209-19
standard. The extrusion machine is preheated
to 140oC, 160oC, and 180oC based on
experimental result, and the screw was set to 7
± 0.3 rpm. The polypropylene waste masks
were directly fed into the barrel without going
through the hopper to avoid getting stuck. After
the purging process, the extruded
polypropylene mask waste was cooled, rolled,
and cut using a chopping machine at 50 rpm.
Melt Flow Rate (MFR) Test for Blending
Polypropylene Medical Mask Waste with
Polypropylene Yarn Grade
In this study, PP waste was tested to determine
the flow rate of melted polymer mixture, which
is essential in determining the processing
temperature for yarn manufacturing. The Melt
Flow Rate (MFR merk Presto), measured in
g/10 minutes, was used as a reference to
determine the ideal temperature variation. The
MFR testing mechanism involved heating the
MFR tool to 200-230oC in10oC intervals. To
ensure accurate data, a mass of 5 g was used
for each MFR test specimen, and at least five
specimens were prepared for each variation. A
purging process was carried out before the
MFR test to avoid residue from the previous
material. The piston gradually descended, and
the flow was calculated according to ASTM
D1238, with the selected time based on the flow
rate of PP, which is >3.5-10 g/10 minutes. The
study aimed to obtain accurate and reliable
data to determine the processing temperature
for yarn manufacturing.
After the yarn was produced, it was visually
inspected to ensure there were no visible
defects or irregularities. Then measured using a
yarn count to determine its size, and this
measurement was compared to ensure that the
yarn was within the appropriate size range. The
yarn used in this study had a Tex value in the
range of 30 – 120, which is the standard size
range for yarn used in shoe fabrics according.
Tensile Test of Yarn
A tensile test was conducted on a specified size
yarn to determine its mechanical properties.
The test was carried out 20 times for each
variation, starting with a calibration stage. The
clamp distance was adjusted to 100 mm (about
3.94 in) ± 1 mm (about 0.04 in), and a test tool
with the principle of a fixed rate of
extension/creep was used as the tensile test
equipment. The stretching speed was set to
100 mm/min with an accuracy of ± 2% and a
100 mm long tensile test sample was used. The
tensile test was conducted until the yarn broke.
The data generated from this test included force
(N) and displacement (mm).
Differential Scanning Calorimetry (DSC)
The Polypropylene waste pellets were then
characterized using DSC, Shimadzu, which is a
technique Thermal analysis has been used for
many years to characterize and measure the
heat flow associated with synthetic
polymers[19]. The DSC analysis provided
valuable information on the quantitative and
qualitative aspects of the involved endothermic
processes and exothermic thermal behavior of
PP waste, which could be used to optimize its
processing and recycling[20-22].
This work used a traditional handloom, which
required manual operation by the weaver. The
process involves inserting the weft yarn through
the warp yarn using a shuttle, which was
passed back and forth by the weaver. The
fabric was woven in a plain weave pattern to
achieve a standard tensile strength of at least
353.1 N in the warp direction and 127.5 N in the
weft direction for every 2.5 cm. This pattern was
achieved by weaving the weft yarn into each
warp yarn in a 1:1 pattern. The tensile strength
requirements for the fabric were based on
industry standards and were chosen to ensure
that the fabric would be suitable for use in
shoemaking applications with a yarn number of
Tex 30-60 or Ne 20-10.
Tensile and Tear test of Fabric
Standard dimensions are used to cut the fabric
for the test, with a minimum of five specimens
required in both the warp and weft diretions. To
prevent slippage during testing, the specimen is
marked before being clamped onto the tensile
tester. The tester then pulls the specimen until
they break, measuring the force (N) and
elongation (mm). The test results are analyzed
to determine if the fabric meets the product
specifications.
The tear test was used to measure a fabric’s
ability to withstand force and resist tearing. The
test was conducted using an Instron. Fabric
samples with dimensions of 200 mm in length
and 75 mm in width are cut, and at least 5
specimens are required for each yarn direction.
The fabric was clamped onto the machine with
a clamping distance of 75 ± 1 mm and pulled at
a speed of 300 ± 100 mm/minute until the
specimen breaks.
Tests were carried out according to ASTM
D7334 using water as the liquid being tested.
The contact angle was selected from the
average measurement of the twelve test
samples [23]. The tool used to see droplets was
a microscope equipped with a goniometer scale
or commonly called the KRUSS DSA100
Geniometer Contact Angle.
3. RESULT AND DISCUSSION
The thermoanalytical method of differential
scanning calorimetry (DSC) is based on the
melting enthalpy of known polymers [24]. DSC
measures heat flow into and out of a material
under a scanning mode of continuous
temperature change. According to Fig. 2, there
were several peaks on the DSC curve with
different directions. The first pointed upwards
and indicated an endothermic process or heat
absorption, while the second and third peaks
were exothermic processes or heat release.
This first peak showed the melting temperature
range of the PP, which started from the onset
point (T = 159.5oC) to the end point (T =
167.2oC) and could be calculated based on the
heat energy required to melt the formed
crystallinity.
Fig. 2 DSC Analysis of Recycled PP: Melting
Temperature and Thermodynamic Properties
The minimum peak in the exothermic direction
indicated that the material released heat,
resulting in a crystallization temperature. When
the polymer chains moved closer to each other
and formed bonds to create a tight structure
(cristallinity/lamella), the temperature continued
to rise, indicating that the crystallization process
was getting faster. Therefore, the data on the
crystallization temperature of polypropylene in
the range of 111.3 oC – 121.8 oC.
Polypropylene was then processed into
continuous yarn with various compositions. It
can be seen visually in Fig.3 At low
concentrations such as 10%-30%, the resulting
yarn tended to be stronger and more elastic.
However, when the concentration was
increased to 40-70%, the thread tended to
become more brittle and prone to breakage
because the material used to make the yarn
became denser and difficult to arrange into a
good structure.
Fig. 3 Yarn 10%wt PP (A), 20%wt PP (B), 30%wt PP
(C), 40%wt PP (D), 50%wt PP (E), 60%wt PP (F),
and 70%wt PP (G).
Therefore, experiments were conducted using a
blend of PP medical masks with yarn grade PP
(10-30%) in the next process to obtain a more
elastic yarn that could be used as a yarn for
shoe fabric. The uneven yarn deteriorates the
appearance of the fabric by producing
undesirable geometric patterns and uneven
color variations due to irregular dye
absorption[25].
Melt Flow Rate (MFR) Blending
Polypropylene Medical Mask Waste with
Polypropylene Yarn Grade
The data described the relationship between
the %wt of polypropylene in a polymer blend
and the tested melt flow rate (MFR). MFR was
a measure of the speed of flow of a polymer
under certain conditions, typically used to
gauge the polymer’s ability for processes such
as molding or injection [26]. The obtained data
indicated that as the %wt of polypropylene in
the polymer blend increased, its MFR value
also increased. The MFR values obtained from
the test results showed fig. 4 that were above
10g/10 minutes, which was the minimum limit
for a polymer to be processed using melt
spinning [27].
Fig. 4 Melt Flow Rate Blending Polypropylene virgin
with polypropylene medical masks.
This was due to the correlation between MFR
and the molecular weight of the polymer [28]. A
higher MFR value indicated that more polymer
flowed[27]. Therefore, the lower the molecular
weight of a polymer, the easier it flowed.
Degradation could lower the molecular weight
of the polymer by breaking the covalent bonds
in the polymer chains. The more PP in the
blend, the more polymers degraded, and
molecular weight became lower.
Measurement of Yarn Number
The yarn number obtained from the melt
spinning process of polypropylene polymer. The
evenness of the yarn is determined by
measuring the core diameter at various points
of the yarn [29]. The yarn is numbered using
the Tex System. The higher the Tex value, the
larger diameter of the yarn, because more
polymer is released from the machine with a
larger diameter. The minimum value of yarn
number that had to be met in making shoes
was 30 Tex, and the yarn number produced in
the melt-spinning process had not reached that
value. Therefore, the yarn process was
numbered to make shoe fabric.
Tensile Test of Yarn
The effect of adding %wt polypropylene on the
yarn's ability to withstand force and prevent
breakage was studied. The tensile test was
used to determine the stretch modulus of
elasticity and yarn tension by withdrawing the
specimen until it broke[30].

Fig. 5 Yarn before tensile test (A), yarn tensile test
(B), and yarn after tensile test (C)
The mechanical analysis in Fig 5a-c indicated a
tensile testing process on the yarn from
polypropylene waste. Shorter chains will hinder
the polymer from forming a neat and tight
structure. therefore, when the yarn was
subjected to a tensile test, the polymer was
unable to transmit the force it received along its
chain, leading to breakage. The fewer bonds
there are in the polymer, the lower its ability to
withstand force. It is important to pay attention
to the quality of the polymer used in making the
yarn so that the resulting yarn has good
strength and durability to meet the need of the
final product, such as shoes.
Fabric Manufacturing
Fabric was made from the yarn produced by
melt-spinning using a screw system, which
used a blend of polypropylene waste from
medical masks and virgin polypropylene. The
use of a cotton-based warp yarn was chosen to
provide breathability to the fabric, which was an
important factor for use in shoe fabrics. The
cotton yarn size used was Ne 7 in both the
warp and weft directions. To use the fabric,
there was a 1:1 weave pattern between the
warp and weft yarns.
Tensile test of Fabric
Fig 6 showed the results of a tensile test on
fabric to determine the tensile strength of the
fabric in the warp and weft directions. The test
on the warp and weft directions showed
differences in tensile strength due to the
different materials used in the warp and weft
directions. Polypropylene yarn was used in the
warp direction, which had a higher tensile
strength than the cotton yarn used in the weft
direction. This could occur because the yarns in
the other direction and the fabric's weaving
construction could also affect tensile strength in
a woven fabric.
Fig. 6a Tensile and 6b tear test of fabric PP
Additionally, in this study, all three fabrics were
made using a weaving machine that could
produce different strengths for fabrics with the
same material because the uniformity level of
the fabric, such as the thread density, could
vary for each variation. Furthermore, the tensile
test results were used to evaluate which fabrics
could be used to make shoes. According to
Indonesian national standards 08-1793-1990,
only fabrics with a minimum maximum force
value of 353.1N in the weft direction and 127.5
N in the warp direction could meet the
specifications. From the above data, only the
fabric with 30%wt PP did not meet the
specifications.
The data on tear strength test results of a
fabric, which is influenced by the material
composition and the construction of the fabric
such as the weave paterrn and yarn density,
are described in fig 9b. The fabric’s tear
strength is measured using the one-peak
calculation method, where the tear strength is
chosen based on the highest peak. The test
results indicate that in the warp direction
(cotton), it is easier for tears to propagate
compared to the weft dorection (polypropylene)
because the yarn in the warp direction has
lower strength compared to those in the weft
direction.
The data also indicates a decrease in strength
of the fabric with a variation of 10-20%wt
polypropylene in the weft direction, which is
caused by the difference in the strength of the
yarn used. However, in fabrics with 30%wt
polypropylene, there is an increase in tear
strength due to the difference in the
construction of the tested fabric. The more yarn
present in the tested fabric, the higher its ability
to withstand the applied force, resulting in
higher tear strength.
Visual Shoe
A prototype shoe was made using a fabric
made of 20%wt polypropylene yarn. The
resulting shoe had a slip-on model with size 38
such as Fig. 7 and looked like a high-quality
shoe that could be found in the market. Visually,
the shoe did not have any defects and was a 167.2°C. Based on this research, a fabric made
good step in reducing the amount of from 20% wt recycled polypropylene waste was
polypropylene waste in the environment. found to be the most optimal choice for use in
shoe production. Through processing and
reuse, polypropylene was recycled in the shoe
industry, and efforts were successfully made to
reduce the environmental impact of medical
mask waste. In conclusion, this study provided
an effective solution in recycling polypropylene
waste from medical masks to produce high-
quality sneakers. Therefore, this research has
significant potential in reducing the
environmental impact of medical mask waste
and promoting sustainable practices in the shoe
industry.
Fig. 7 shoe manufacture with polypropylene waste
pair of uppers (A), left side (B), and upper (C) ACKNOWLEDGMENTS
The authors wish to express their sincere
4. CONCLUSION
thanks for the collaboration with Kitakaya
This study succeeded in recycling Raharja Indonesia Inc., which is gratefully
polypropylene waste from medical masks to be acknowledged for the help rendered such as
broken white sneakers with size 38 from polypropylene virgin for making fabric shoes.
medical mask waste from medical masks. The This work was supported by Bandung
DSC characterization results showed that the Polytechnic Textile, and Indonesian National
melting temperature of recycled polypropylene Agency for Research and Innovation (BRIN,
from medical mask waste ranged from 159.5- Indonesia).
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