This innovation relates to the preparation of improved process of recycling waste plastic comprising of Low-Density Polyethylene (LDPE), High Density Polyethylene (HDPE) & Poly propylene (PP) blended with rice husk ash in the presence of suitable compatibilizer and calcium silicate and making granules which can be used in fabricating pallets, interlock tiles and other products which have usage for industry and startups. Plastics occupy an indispensable position in human life but still, it is a villain in disguise as its non¬biodegradable nature and extremely high durability leads to many hazards for humans and their surroundings. The indiscriminate dumping of plastics has led to many environmental challenges and made it an issue of utmost interest as recycling of plastics is leading to roadblocks due to their inability to degrade. Thus, it is one of the most non-biodegradable material ever produced by man himself. Plastic waste disposal is a major environment challenge as all the packaging materials are composed of LDPE or their analogues. Burning or banning plastics are not the only solutions as these are the main source of environmental pollution. Our modified innovation looks into different aspects of recycling of waste plastic which when incorporated and blended with specific fillers gives a recycled product having better mechanical strength, better skid resistance, improved flame retardancy and resistant to acids and bases besides better sound reduction capability.
3. BACKGROUND INVENTION
Plastics have numerous applications and mostly all the plastics put to use is disposable which is when thrown to land makes the soil less fertile and when thrown into water bodies it chokes the rivers, ponds, etc. and also cut down the supply of oxygen for aquatic life thereby threatening their survival. It keeps on littering and adding to environmental pollution. Most of the discarded plastic is sent to landfills, where they are buried deep inside the soil away from the direct sunlight. Plastics which have slow rate of degradation on being shielded from sunlight will take more

than thousand years to degrade completely inside the landfills. Also, during the degradation process, they leach out toxic gases which can pollute the groundwater levels and also severely affect the fertility of soil. If left open in environment it will rot and decompose releasing harmful gases like carbon dioxide and methane which being the greenhouse gases adds to global warming causing further deterioration of environment. The plastic waste buried in ground if encountered can harm the human, natural flora and fauna and animals as the toxins released in ground can run off to streams and water bodies that supply drinking water thereby causing carcinogenic diseases. On the other hand, burning the plastic waste is also problematic, as on burning plastics releases many harmful toxic gases which if inhaled by living organisms can severely affect the health and cause serious respiratory disorders. Also, one kilogram of plastic on burning will release three times, i.e., about three kilograms of carbon dioxide leading to global warming. Although recycling of plastic waste is a tricky business, but it is far better than dumping them to landfills or burning them in incinerators and causing further degradation of already polluted environment. Also, it takes only one-third of the energy required to make plastic products from virgin plastics to make products from recycled plastic. It is estimated that as of now about 8300 million metric tons of plastic has been produced and out of which 6300 million metric tons has been added to the solid waste stream. According to the available data only 9% of plastic waste has been recycled, 12% incinerated and 79% has been accumulated in the landfills or the natural environment, till year 2019. If severe steps are not taken at the moment to control the current trends in production and recycling of plastics, it is estimated that by 2050 approximately 12,000 metric tons of plastic waste will be out there in the natural environment making it a hideous site.
Several hundred million tons of plastic waste is generated worldwide out of which only 60% is recycled in India, about 10% in USA and even less percent in other countries and rest non-recycles plastic waste is thrown away in the environment. The careless disposal and dumping of plastic waste by consumers have become an environmental nuisance. All the plastic waste which is not recycled accumulate in ugly heaps alongside roads and ultimately increase the volume of

waste being dumped or burned in dumpsites and landfills. The conventional methods for plastic waste disposal are material recycling, landfills, incinerators and energy conversion.
Recycling is clearly a waste-management strategy, but it can also be seen as one current example of implementing the concept of industrial ecology, whereas in a natural ecosystem there are no wastes but only products. Recycling of plastics is one method for reducing environmental impact and resource depletion. Fundamentally, high levels of recycling, as with reduction in use, reuse and repair or re-manufacturing can allow for a given level of product service with lower material inputs than would otherwise be required. Recycling can decrease energy and material usage per unit of output and so yield improved eco-efficiency. Although, it should be noted that the ability to maintain whatever residual level of material input, plus the energy inputs and the effects of external impacts on ecosystems will decide the ultimate sustainability of the overall system. The challenge of disposing of plastics in municipal wastes has received little public attention until recently. The material has simply been buried or burned. But the rising costs of landfills, and of transporting wastes to other states, reduced availability of space and concern about the health implications of incinerating some materials, have forced states to seriously consider recycling or the use of alternative materials.
With enormous amount of plastics being generated every year, it's recycling and processing becomes a major challenge. Plastic waste recycling should be carried out with the primary aim of minimizing the amount of pollution during the process along with enhancing the efficiency of process by energy conservation. Plastics recycling technologies have been historically divided into four general types -primary, secondary, tertiary and quaternary. The amount of plastic waste generated is mirror to the economic levels of population from where it originates. Basically, there are two types of plastic waste, namely primary and secondary plastic waste, that is being generated worldwide and a distinction between them is relevant for proper recycling and re-processing.
The plastic waste, which is produced within the plastic goods producing, and

manufacturing industries are known as Primary waste plastics. This type of waste is pure and most suitable for reprocessing, as the quality of plastic recovered is almost as high as virgin plastic. The processing of primary waste into products with characteristics similar to those of the original products is called primary recycling. Primary plastic waste is usually homogeneous and therefore its recycling is comparatively economical and easier. On the otherhand, "secondary waste" refers to waste plastics from sources other than the industrial ones. This type of plastic waste is generated due to the consumption and littering habits of the people in an community. This type of plastic waste is impure, i.e. it may be conatminated and mostly consists of mixtures of different types of plastics. The method for reprocessing of mixture of plastic wast is called secondary recycling. The recycling or reprocessing of plastics is the process by which waste plastic material that would otherwise become solid waste are first collected, sparated and then processed for re-utiization.
Following are the works done so far in the field of waste plastic utilization for different industrial applications:
WO2013057737A2 (25.04.2013): Process of recycling plastics, products and applications thereof (Inventor: Natarasan Sethu, Chandrashekhar Ramchandra Abhyankar, Mrinal Kanti Banerjee)
The present disclosure relates to a process for recycling of plastic waste comprising: segregating plastic waste collected from various sources followed by cleaning of the segregated plastic waste to obtain segregated cleaned waste; grinding of the segregated cleaned waste to obtain grinded waste; introducing the grinded waste into an extrusion line having a venting extruder component as part of the extrusion line, to obtain molten plastic; and removing the impurities by vacuum venting of the molten plastic to obtained recycled plastic free from impurities. The present disclosure further relates to various articles like Industrial Post Recycled (IPR) plastic tubes, blow moulded bottles, pallets, manufactured from the recycled plastic waste. The present disclosure further provides a simple and an economical process for separating post industrial and post-consumer plastic tubes into groupings based on a selected coding/ identification system. The present disclosure can be used to

purify a number of polymers that may conveniently work in an extruder operating environment. As stated, the disclosed process is particularly suited to recover recycled purified plastic from scrap of postindustrial used plastics. Whereas our innovation describes a process of utilization of waste plastic and blending it with other waste fillers like agriculture waste, coal tar waste and adding specific fillers so that the resultant granules can be used in designing pallets for warehouses or interlocking tiles for pavement for non-vehicular movement and having antistatic and anti-skid characteristics.
US Patent application No. US 2007/0149625 Al discloses a process and an apparatus for the recycling of waste plastics found in municipal solids waste. It also discloses a process for recycling plastic material by providing a common dielectric property to the plastic material and treating the plastic material using microwave energy. There is a need to develop a processing technique to remove both volatile and non-volatile contaminants which can provide high quality plastic material from recycled plastic and can be used as a substitute of virgin material. The improved recycling process should reduce/ reuse waste, should be economical, energy efficient, reduce carbon footprint, help in environmental protection and deliver a new end-product with high technical features. Whereas our innovation step does not involve use of microwave energy to separate the constituents in plastics and follows a different methodology to utilize waste plastic in designing different products with better mechanical strength and having unique sound barrier characteristic.
Patent No. 202532, Indian Patent Application Number 772/KOL/2004 -Improved Eco-friendly recycling process of post-consumer waste plastics and device thereof (Prof Dr. Sadhan Kumar Ghosh)
The present invention relates to an improved eco-friendly / green recycling process of post-consumer waste plastics and a device thereof. The main goal for developing eco-friendly / green recycling of post-consumer waste plastics is to design an extruder (1), which would have "Zero Significant Adverse Environmental Impact". This has been achieved by assigning right collection method, right equipment, heat sealing and right temperature for the processes and trapping all the emission in

pollution control gadget (12, 13) and treating the pollutants to produce by-products for commercial utilization. The present invention identifies pollutants generated and reduces the level of emission to air to a minimum from the process thereby reducing energy consumption with better product quality. Collection & segregation methods for the recycling process of post-consumer waste plastics have been delineated in the present invention. The extrusion process has been re-engineered to reduce and control the emission generated during the post-consumer waste plastics recycling. Post-consumer waste plastics recycling has three phases (i) material recycling to recycle plastics to plastic materials, (ii) chemical recycling to chemically dissolve the plastics back to the raw material (monomer), and (iii) thermal recycling to utilize plastics as a heat source. Among these methods, material recycling and investigation of technical methods for reusing post-consumer waste plastics for packaging and other purposes as well as collected plastics of known origin have been focused in the present invention. Plastic waste management reengineering of the recycling process of packing plastic, and more particularly, the recycling process of post-consumer waste plastics heretofore devised and utilized are known to consist basically of familiar and expected processes, notwithstanding the myriad of processes encompassed by the crowded prior art which have been developed for the fulfillment of countless objectives and requirements. Existing recycling process comprise the following steps of collection, selection, segregation and processing of post-consumer waste plastics. Whereas our innovation involves use of utilizing waste plastic along with other agriculture waste and coal tar waste in designing materials which have improved anti-skid and anti¬static characteristic.
US Patent 4,828,896 (1989) - PATTERNED THERMOPLASTICS TILE AND METHOD OF MAKNG SAME, Inventor: Luigi Fanti, Styvechale, United Kingdom; Assignee: Courtaulds PLC, United Kingdom
A plastics tile has a back ply having raised areas on one face which define at least one recess and a slug of facing material bonded in the or each recess. The slug or slugs are desirably either flush with or slightly proud of the raised areas of the back

ply. The object of the present invention is to provide a method of manufacturing tiles which can enable a simi lar patterned appearance to that described above to be achieved but without the disadvantage of leaving gaps between the slugs which can collect dirt but which also enables new pattern effects to be achieved, especially if hygiene requirements are set no higher than with previous tiles. Whereas our innovation follows different terminology and concept in designing granules which can be used in making pallets or other products which have better industrial and municipal corporation usage application.
US Patent 5741454 A (1998) - Method of making composite tiles containing waste plastic, Inventor-Athos Polidori (Saludecio, Italy) describes a Method of making composite tiles containing waste plastic. The invention relates to taking of plastic materials composed of the waste of some industrial processes (for example in the shoe-making sector), and/or coming from plastic objects of current use being put out of use, are frequently crushed to be used again in subsequent transformations. The invention solves the problem of making, by means of a suitable manufacturing process, a composite tile in which plastic material of a suitable quality for the environment in which the tile will be used is injected into a mould so as to form an outer shell of the tile, inside which, at a later stage, waste plastic material is injected with the function of filling the tile. However, our invention relates to the usage of waste plastic comprising of LDPE, HDPE, PP and the like, adding waste from agriculture rice husk and from coal tar and adding specific flame retardants and UV absorbents in fabrication of pallet or interlock tiles which does not make use of any virgin plastic.
Patent No: A-CH\871. Reg No: 198254, Dt. 27-06-2002 - Utilization of Waste Polymers for Flexible Pavement and Easy Disposal of Waste Polymers, R.
Vasudevan, S.K. Nigam, R. Velkennedy, A. Ramalinga Chandra Sekar and B. Sundarakannan relates to describing a new mix process of waste plastic-aggregate bitumen for flexible pavement. Waste plastics have binding property in their molten state. Using this property, waste plastics, aggregate and bitumen mix having waste plastics up to 2 parts by weight, bitumen 3-6 parts by weight and the aggregate 92 to 95 parts by weight. The mix then used for flexible road

construction. A process of manufacturing the above said waste plastics-aggregates-bitumen mix (composite) is having the following steps, a) Sorting and cleaning of waste plastics to identify polyethylene, polypropylene and polystyrene and to reject polyvinyl chloride, b) Shredding the film to a size, which passes through 6.75mm sieve and retains in 2.36mm sieve c) Heating the aggregate to 155- 165deg.C d) Heating the bitumen separately to 160deg.C (should not be heated more) e) Adding the plastics pieces over hot aggregate, having chosen composition and mix it through puddler for uniform coating, f) Add the hot bitumen (160deg.C) over the plastics coated aggregate and mix it uniformly, g) Waste polymer-aggregate -bitumen mix is now taken for road laying. A method of manufacturing the mix (composite) of waste plastics-aggregate-bitumen as described in the complete specification of this invention. Whereas our innovation does not make use of waste plastic in bitumen but follow different concept and terminology for utilizing waste plastic wherein agriculture waste from rice and coal tar waste are added for making pallets and tiles.
US 8344195 B2, January 1, 2013, Process for producing fuel from plastic waste using dolomite catalyst - by Jumluck Srinakiruang, Bangkok (TH) describes a process for producing fuel from plastic waste material by using dolomite catalyst. Herein the invention describes a process for producing fuel by cracking a plastics-derived liquid, which is obtained from a pyrolysis process, using a dolomite catalyst. The plastics-derived liquid is produced by the pyrolysis of plastic waste, such as of one or more of polyethylene, polystyrene or polypropylene. The plastic-derived liquid is first subjected to a semi-batch catalytic cracking reaction over a very low-cost dolomite catalyst to obtain high quality oil for fuel, which comprises mainly light and heavy naphtha. Moreover, the catalytic cracking reaction is conducted at operating temperatures lower than 320° C. Another object of the present invention is to provide a process for disposing a large amount of plastic waste by using an environment friendly process at low operating temperatures. For example, it is very hard to decompose polyethylene at temperatures below 450° C. and large amounts of decom posed residuals are generated. However, the technology of the present invention can solve the foregoing problem and provide high reaction efficiency

to decompose polyethylene, a linear chain molecule that is difficult to decompose, at temperatures lower than 400° C. Whereas our innovation relates to the designing of pallets from waste plastic and other waste so that these can be used for making specific designed products.
Process for waste plastic recycling Sep 6, 1995 - The University of Wyoming Research Corp.,
US 5753086 A (1998) describes a process which overcomes the above-mentioned deficiencies in the prior art and to a process which achieves decomposition of waste plastic at a relatively low temperature. As one example, the process decomposes a mixed stream of waste plastic at a temperature generally less than 375.degree. C. in a hot oil medium. The process converts the polymeric structure of the waste plastic or plastics to smaller chemical molecules such as the monomeric units and related chemical structures at a relatively lower temperature. It also serves the market for the such products. Since this market is not a to-be-developed manufacturing process, but rather one for which existing plants in the refining and petrochemical industries already exist, the process is adaptable to existing facilities that are already experiencing limited supplies of low molecular weight, heteroatomic free feedstocks from petroleum crude oils. The low-molecular weight distillate from waste plastic processing according to this invention may help reduce the demand for imported petroleum products and help decrease our dependence on foreign crude oil.
U.S. patent number 11,020,751 (01.06.2021) [Application Number 14/721,348]
was granted by the patent office for Reparation process for plastics materials. This patent grant is currently assigned to Berry Plastics Corporation. The grantee listed for this patent is Berry Plastics Corporation. Invention is credited to Robert Flores.
A separation process comprising: introducing a plastics material having a first material density and a plastics material having a second, different material density into a tank, separating the plastics material having a first material density from the different plastics material having a second material density using fluid comprising vegetable oil and an additive, wherein the separating includes agitating in the tank, wherein the fluid has a fluid density greater than the second

material density. The separation process of claim 1, wherein the second material density is in a range of 0.89 g/cm3 to less than 0.92 g/cm3. According to the present disclosure, various types of plastics materials are separated from one another in a materials-separation process. The process may be used to sort a first plastics material from a second plastics material. In the material-separation stage, the higher-density separation operation is carried out in which flakes made from all of the plastics materials are placed in a higher-density fluid separator that allows flakes made of a first plastics material to sink in the higher-density fluid and thus be separated from flakes that are made from a second and third plastics material float in the higher-density fluid. For example, various plastics materials such as polystyrene (PS), polyvinyl chloride (PVC), and polyethylene terephthalate (PET) sink in the higher-density fluid. Other plastics materials such as polypropylene (PP) and high-density polyethylene (HDPE) float in the higher-density fluid. Whereas our innovation describes a process for utilizing waste plastic in designing various products for their end industrial applications.
Waste plastic additive for asphalt - US 6,844,418 B2 Jan. 18,2005, Inventors: John M. Forgac, Elmhurst, Ashok S. Muzumdar, Arun K. Singhania, April J. Swanson, Anderson, Assignee: BP Corporation North America Inc., Warrenville, IL(US)
The present invention provides an improved polymer additive which may be used to increase the high temperature Viscosity of an asphalt, without deleteriously affecting the low-temperature Viscosity of the asphalt. The polymer additive may also be used to improve the Stiffness of certain asphalts. The polymer additive is produced from readily available polymer blends by a thermal process. The invention additionally provides an improved polymer modified asphalt. In its preferred embodiments, the invention also provides an environmentally acceptable method for recycle of post-consumer carpet and bottles. Whereas our innovation describes a process of recycling of waste plastic along with other agriculture and coal tar waste and designing suitable products for industrial applications.

Plastic asphalt paving material and method of making same - US Patent No.
6000877 A, 14.12.1999, Inventors: Fishback Gary, Egan Dennis, Stelmar Hilary, Assignee
PI asphalt Project Ltd. Co. USA
An asphaltic concrete or paving material includes at least 5 percent, and preferably from 5 to 20 percent, of granular recycled plastic, which supplements or replaces the rock aggregate component of the mixture. The material produces a structurally superior paving material and longer-lived roadbed. The plastic may include any and all residual classes of recyclable plastic, including thermosetting plastics and other plastics having little to no current widespread utility. The material produces roadbeds of higher strength with less total asphalt thickness and having greater water impermeability, and is most useful for all layers below the surface layer. The recyclable plastic component of the material is preferably a mixture of all recyclable classes 3 through 7, or of those materials from such classes from which potentially more valuable recyclable materials have been selectively removed. The paving product is preferably formed by a process of shredding or mechanically granulating used and industrial waste plastic to a no. 4 to 1/2-inch sieve size, and preferably to 1/4 inch to 3/8-inch granules. The granules are then treated with an energized activating medium such as a plasma or a reducing flame, to activate the surface of the granules, preferably without burning or melting the plastic. The activated treated granules are then added to the aggregate and mixed with the asphalt binder to produce the paving material. A slurry or sand mix of plastic and binder may also be applied over an aggregate layer, base layer or roadbed. Whereas our invention makes use of waste plastic in designing pallets and interlocking tiles where waste from agriculture and coal tar are added to make the final product.
Composite Tiles Prepared from waste plastic and a process for the preparation thereof - Application ID 201611025127 (22.07.2016), Applicant CSIR, New Delhi.
The present invention relates to a composition for flame retardant composite tiles prepared from waste plastics and a process for making such tiles. Disposal of

Plastic waste is a major problem. It is non-biodegradable & it mainly consists of low-density polyethylene plastic bags, bottles etc. Burning of these waste plastic bags causes environmental pollution. The instant invention relates to providing composite tiles by in-situ incorporating various fillers in shredded waste plastic followed by compression moulding the composite at a specific temperature while taking care of various issues like mechanical strength, flame retardancy, water permeability and UV- protection from sunlight and antistatic response. The prepared tiles are immensely useful in construction sector such as in building toilets and rooms for general public and to serve societal benefits. Disposal of waste plastic bags is a major problem. It is non-biodegradable & it mainly consists of low-density polyethylene bags, plastic containers and bottles. Burning of these waste plastic bags causes environmental pollution. The main objective of the present project is to utilize waste plastic bags for designing of tiles in building of structures and rooms for general public for societal benefits. Among different plastic solid waste being generated, plastic bags composed of LDPE are major source of waste. Thus, in this study, waste plastic bags are used as matrix reinforced with fly ash, another type of commercial waste, to make composite tiles which can be put to use for building structures for societal benefit. The results showed that filler loadings have positive effect on the properties of plastic waste matrix. Thus, the composite tiles fabricated put forward a newer approach for re-utilization of waste plastic material in our day to day life and industry in an environmentally friendly and economical way. They can be used to build structure which will be light weight, resistant to corrosion, chemically resistant, low cost of production, increased service life and most importantly put into use what is the menace for society- Plastic waste. Whereas the present innovation is an improved process of utilizing waste plastic like LDPE, HDPE, PP and their analogues by blending these with agriculture waste like rice husk ash and coal tar waste and adding specific fillers and gas powder so that the blended product gives excellent flame retardancy and better antistatic and skid resistance and sound inhibition behaviour.

US Patent 5801204 (1998) describes a method of reclaiming waste plastic material and a compound including waste plastic material. Herein, waste plastic material is treated so as to make possible its utilization as a binder component in road surfacing materials, as a fuel, or for other desirable purposes. The waste plastic material is made at least partially fluid by mixing it with a solvent. The solvent is waste fats produced in refining or by treating animal and/or vegetable fats, crude fatty acids obtained as byproducts of refining fats, or fatty acids or pitch obtained by distilling hydrolyzed fats. The solvent is typically mixed with waste plastic material in the ratio of less than 1:2, preferably about 1:3, and at a
temperature of between about 150 ° - 250° C.
Process for construction of artificial roads, walk ways, footpaths, etc. from waste plastic, plastic type resins and related polymers - WO 2017093822A1, Applicant Bharat Petroleum Corporation Limited, Mahesh Kastur, A process for construction of roads, walk ways, footpaths, pavements, etc. from unsorted waste plastics of various types and origin, plastic type resins and related polymers comprising: - laying at least one sub-base layer of hollow blocks such that the hollow blocks lie horizontally adjacent to each other; - filling the said sub-base layer of hollow blocks with bituminous mixture or asphalt or road paving material; - optionally covering the said filled hollow blocks with covers/lids; - laying at least one base layer of hollow blocks over the sub-base layer such that the hollow blocks lie horizontally and vertically adjacent to each other; - filling the said base layer of hollow blocks with bituminous mixture or asphalt or road paving material; -optionally covering the said filled hollow blocks with covers/lids; - laying the surface layer with road base materials or bituminous mixture or asphalt. Whereas our innovation doesn't make use of bitumen or asphalt in designing of end products like pallets or interlock tiles.
European Patent Application 0664 314 Al: Polymer recycling by selective dissolution, Applicant: RENSSELAER POLYTECHNIC Institute, Troy, NY, Nauman, Bruce E., Lynch, Jerry C - A method for separating polymers from a physically commingled solid mixture containing a plurality of polymers comprises dissolving a first one of the polymers in a solvent at a first lower temperature to

form a first preferably single-phase solution and a remaining solid component. The solid component contains additional polymers which are not soluble to the solvent at the first temperature but which may be soluble at higher temperatures. The method includes subsequently heating the solvent to dissolve additional polymer from the solid component to form subsequent solutions. The polymers are then separated from their respective solution either using flash evaporation techniques when more than one polymer has been dissolved at a single temperature, or conventional techniques for extracting a polymer from a solvent in a solution.
EP1673204A1: Process for recycling waste plastics - Inventor David James Lark, William Alexander Howell, Current Assignee Cyclopias Holdings Pty Ltd - A process for recycling plastic material by reducing a sample of plastic material to form plastic particles having a desired particle size; providing a susceptor agent to the plastic particles which imparts a dielectric property to the plastic particles; providing a bonding agent to the plastic particles; and treating the plastic particles with microwave energy to form a useable plastic material. The present invention relates to a process and apparatus for the recycling of waste plastics such as are found in municipal solids waste. The invention also relates to a wide range of value-added items produced from the recycled plastic.
US - 5560797-A - Methods of making floor tile and wall covering from extruded hot recycled vinyl thermoplastic membrane having discrete fibers randomly dispersed therein; Inventors-Burt John R, Szabo Kenneth A, Stewart Ronald L - A method of continuously fabricating a cushiony recycled plastic floor tile or wall cover wherein a single-ply sheet, made up substantially of recycled membrane and a proportion of discrete fibers sufficient to create a cushion effect in the tile, is extruded. The fibers are reduced in length by cooling the sheet extrudate produced, chopping the sheet extrudate into particles in which the fibers are reduced in length and then passing the chopped extrudate into the extruder to re-extrude it. When size reduction is achieved, the hot substrate proceeds immediately into the nip between laminating rolls and a preheated cover film selected from the group comprising transparent sheet, colored sheet, and sheet with decorative imprinting is passed on into the nip with the substrate. Compressive pressure is applied by the

laminating rolls to autogenously heat weld the substrate and cover film in surface-to-surface sealed contact without the imposition of air bubbles or wrinkles between them. The welded product is then cooled and cut into discrete sizes.
US 6,583,217 Bl, June 24, 2003, COMPOSITE MATERIAL COMPOSED OF FLY ASH AND WASTE POLYETHYLENE TEREPHTHALATE -
Inventors: Yadong Li, FloWood, R. Lee Peyton, Rocheport, David J. White, Assignees: Iowa State University Research, Inc., Ames, IA (US); The Curators of the University of Missouri, Columbia, MO (Us) - A composite material and method are described Wherein melted Waste, chemically unmodified PET material and flyash particles are mixed in a vessel to disperse fly ash particles in the melted PET material. The resulting mixture then is cooled to solidify the melted PET material to form a composite material having a matrix comprising PET and dispersoids distributed in the matrix and comprising fly ash particles. In one embodiment of the invention, the solid Waste, chemically unmodified PET material and fly ash particles are premixed and placed in the container for melting of the PET material While the mixture is mixed or stirred. Alternately, the solid Waste, chemically unmodified PET material can be melted in the container, and fly ash particles introduced to the melted PET material with mixture stirred or mixed. The mixture of fly ash and melted PET material can be molded, extruded or otherwise formed to shaped articles of manufacture or may be used as a protective coating on a substrate. The invention envisions use of Waste PET material from recycled beverage bottles and other sources. In practice of the invention, the recycled Waste PET material is not chemically modified in any Way prior to melting. The solid recycled Waste PET material may be Washed in tap Water and shredded or otherwise comminuted prior to melting. The invention envisions use of different types of fly ash particles including relatively high lime, cementitious ASTM class C and/or relatively low lime class F type fly ash. Preferably, the fly ash comprises relatively high lime ASTM class C fly ash and fly ash with comparable morphological characteristics. Various amounts of fly ash up to about 70 wt. % fly ash can be included in the composite material. Preferably, the fly ash content of the composite material is at least 50 Weight % and preferably from 50 to 70 wt. %.

US20130102707A1: Carpet waste composite, Inventor, David E. Murdock, Douglas Mancosh, James P. Przybylinski, Current Assignee MATERIAL INNOVATIONS LLC , USA
A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material. This invention relates to systems and methods for fabricating plastic composites (PCs) and, more particularly, to systems and methods for plastic composites that employ recycled carpet waste as a component of the composite.
Application No.202021046810 A - PROCESS OF MANUFACTURING GLOWING TILES FROM PLASTIC WASTES, Sachin Kumar S Yadav, Sonali Kumari, Anubhav Yadav, Shailesh Kumar, Ranvir Kumar
A process of manufacturing glowing tiles from plastic wastes is disclosed. The process includes cutting the plastic wastes into smaller pieces using at least one of scissors, cutters, or shredding machines. The process further includes mixing the smaller pieces of the plastic wastes with sand or stone dust or churi gitti to obtain a first mixture. The process further includes melting the first mixture in a melting machine to obtain a melted mixture. The process further includes molding the melted mixture in a molding machine to mould the melted mixture into tile shape to obtain tiles. The process further includes applying epoxy resin and radium on the tiles to obtain the glowing tiles.
Indian Patent Application No.201921009952 A: P-MATERIAL: Waste Plastic Convert into a pipe, tiles & other materials - Vemuri Venkata Phani Babu, A. Vanamala Kumar, P. Ila Chandana Kumari, Sandesh Patil, Aditya Rajkamal Sharma, Pramod Subhash Warshetti, Yashpal Singh, Biplab Kumar Sarkar

This "P-Material" is very useful for protection of environment, The Municipal waste collected as garbage contains significant % of thermoplastic waste. After separation from non-plastic waste the thermoplastic waste can be given catalytic pyrolysis treatment and different material fractions can be separated by process of fractional distillation. We have carried out 2 stage fractional distillation of plastic waste to generate usefully plastic material with conversion efficiency 85.7%. Catalysts play an important role in pyrolysis of plastic waste. Many catalysts either enhance yield or quality of Plastic Material in pyrolysis while some catalysts are expensive and not easily available. Many catalysts are not thermally stable at room temperature and their storage is difficult while some decomposes at lower temperatures i.e., below 45.5A°C. So, for sustainable plastic waste treatment by pyrolysis, catalyst should be cost effective, easily available, and thermally stable at higher temperatures and should enhance both yield and quality of Plastic material. Out of different catalysts tried in pyrolysis, Dolomite, Solicited, Flash and Alumina fulfilled the criteria, so pyrolysis experiments carried out by using these. From experimental results, it is concluded that out of Dolomite, Solicited, Flash and Alumina, Dolomite and Flash enhanced yield of liquid product as compared to that of simple pyrolysis. 5.5 to 10.9 wt. % catalysts to that of plastic waste found optimum for enhancing yield of Plastic material in pyrolysis process.
CN202656344U (1.09.2013): Fi Hong Fu, Waste plastic disposal and utilization system
The utility model discloses a waste plastic disposal and utilization system, aiming to solve disadvantages in two aspects of the prior art as follows: firstly, the technical process is fussy as pelletizing is firstly performed and then the pelletized waste plastic serves as a raw material to be used for producing products when the conventional waste plastic is recycled and utilized, and energy is wasted as the afterheat of equipment is unutilized; and secondly, harmful gases which pollute the environment are generated as a filtering screen of the conventional filtering device used for filtering the waste plastic in a melting state needs to be detached for cleaning in a burning manner after a period of time of use, and the production efficiency is reduced as the filtering screen is detached after a machine is halted.

The waste plastic disposal and utilization system, disclosed by the utility model,
has the advantages of being unnecessary to pelletize in the recycling process of the
waste plastic, being simple in technical process as the waste plastic enters in from
a feeding port to form a product from a mould after being subjected to a treatment,
saving electric energy as the afterheat of the equipment is utilized, preventing
harmful gases generated caused by burning as cleaning in a burning manner is
unnecessary for the filtering screen, and improving production efficiency as the
equipment can work continuously without stopping. Whereas our innovation
involves different methodology and concept in designing granules from waste
plastic and making final product. Our innovation ensures that no hazardous gases
like SOx, NOx and VOC are released and our products possess better anti-skid
behaviour and antistatic response which is the novelty concept of our innovation.
CN102321348B - (26.12.2012) - Method for preparing plastic tray from three-layer composite
film recycled material, Zhang Hua Ji, Chen Jio & Zhang Veno, Fujian National University
The invention relates to a method for preparing a plastic tray from a three-layer composite film recycled material serving as a basic raw material. The method comprises the following steps of: taking 87 to 92 weight parts of three-layer composite film recycled material, 6 to 10 weight parts of butyl acrylate grafted linear low-density polyethylene (LLDPE-g-BA), 0.6 to 1.0 weight part of tris-(2,4-di-tert-butyl-pheny) phosphite, 0.4 to 0.7 weight part of tris(l,2,2,6,6-pentamethyl-4-piperidine)phosphite, 0.5 to 0.8 weight part of rutile type titanium dioxide and 0.3 to 0.5 weight part of phthalocyanine green, and performing crushing, drying, mixing, extrusion and injection molding. Compared with a wooden tray, the plastic tray prepared by the method has the characteristics of high compression strength, high stretchability, acid and alkali resistance, capacity of being easily washed and disinfected, no mildew and the like, and is suitable for the industries of machines, electronics, foods, clothing and the like. Whereas our innovation doesn't make use of these fillers or design tray but follow different methodology for designing pallets for ware houses or interlock floor tiles.

4. Objective of the Invention:
Plastic menace has created a huge problem in the present time and its disposal is a major problem not only in India but all over the world. Plastic waste comprising of different categories like low density poly ethylene, high density polyethylene, poly propylene, poly styrene and others does nor degrade or disintegrate which creates a major environmental problem. Our thinking is that banning or burning plastic are not the only solution and our innovation is a solution to the utilization of waste plastic in fabricating different products like pallets, interlock floor tiles, pavement tiles by blending waste plastic with other waste from agriculture like rice husk ash and coal tar waste by utilizing microsphere carbon microbeads (MCMB). Objective of our innovation is to blend waste plastic like LDPE, HDPE & PP with other specific fillers and design products which can find industrial & practical applications.
5. Summary of the invention:
The present invention provides a process of utilizing plastic waste scrap encapsulated with rice husk-ash, stearic acid coated calcium silicate, UV retardant and meso carbon micro beads and designing a pallet and interlocking tile which can be used as a base for storage of items in warehouses or for pavements or for making roof and floor tiles. The method comprising:
(a) Collecting the waste plastic and separating waste plastics as per their coding or by separating by density rule for separation of various plastics and blending it with rice husk ash, stearic acid coated calcium silicate, adding specific UV retardant and MCMB and master batch and the like.
(b) Mixing the waste plastic along with fillers in high-speed mixer and extruding it in extruder and making granules by selecting specific ratios of waste plastic like LDPE, HDPE & PP and other fillers.
(c) Making specific product in injection moulding machine using pre-fabricated die moulds and making pallets or interlock tiles as per the specifications.

(d) Testing the product as per ASTM specifications
In one embodiment of the invention, the shredded plastic was mixed with rice
husk ash and MCMB in various proportions so that the blend possesses specific
antistatic behaviour and sound barrier property.
In another embodiment of the invention, the calcium silicate coated with stearic
acid was used for getting better strength and improved flame retardancy.
In another embodiment of the invention, magnesium hydroxide coated with
stearic acid was used to provide better flame retardancy in the blended plastic.
5. Summary of the Invention
The recycling of plastic waste in fabrication of pallets and interlock tiles has large environmental value as it consumes one of the most polluting products of modern time. Fabrication of rice husk ash waste plastic blended pallets and interlocking tiles along with stearic acid coated calcium silicate and incorporation of specific filler like meso carbon micro spheres with different combinations are the novelty steps of the innovation. India is likely to increase its plastic consumption manifolds in coming years and disposal of waste would be a major challenge. This innovation not only provides a sustainable living for the people who are collecting them from the garbage but also convert waste into a useful product and saves the environment. Thus, these tiles can be boon to plastic recycling industry and with their light weight, better characteristic and cost-effective designs can give a tough competition to convention wooden, cement and ceramic tiles.
6. Detailed Description of the invention:
Recycling is clearly a waste-management strategy, but it can also be seen as one current example of implementing the concept of industrial ecology, whereas in a natural ecosystem there are no wastes but only products. Recycling of plastics is one method for reducing environmental impact and resource depletion. Fundamentally, high levels of recycling, as with reduction in use, reuse and repair or re-manufacturing can allow for a given level of product service with lower material inputs than would otherwise be required. Recycling can decrease energy and material usage per unit of output and so yield improved eco-efficiency.

Although, it should be noted that the ability to maintain whatever residual level of material input, plus the energy inputs and the effects of external impacts on ecosystems will decide the ultimate sustainability of the overall system. The challenge of disposing of plastics in municipal wastes has received little public attention until recently. The material has simply been buried or burned. But the rising costs of landfills, and of transporting wastes to other states, reduced availability of space and concern about the health implications of incinerating some materials, have forced states to seriously consider recycling or the use of alternative materials. With enormous amount of plastics being generated every year, it's recycling and processing becomes a major challenge. Plastic waste recycling should be carried out with the primary aim of minimizing the amount of pollution during the process along with enhancing the efficiency of process by energy conservation.
The disposal and recycling of waste plastic is thus a major challenge. In this innovation, waste plastic packaging materials, milk pouches made up of low density poly ethylene, plastic scrap made up of HDPE & PP are recycled and blended with specific fillers and fabricated them into granules leading to the formation of pallets, interlocking tiles and other products which can be used in storage houses, warehouses, pavement laying and for floor tiles. The innovation provides a solution for solid waste plastic management problem and promote waste-to-usable technology program, a much-needed impetus to India's recycling industry. The use of plastic waste in fabrication of pallets and interlocking tiles has large environmental value as it consumes one of the most polluting products of modern time. India is likely to increase its plastic consumption manifolds in coming years and disposal of waste would be a major challenge.
The primary step for the recycling waste plastic is the collection and segregation of plastic waste according to codes given by Society of plastic Industry (SPI). Thus, for this purpose waste packaging materials, discarded waste milk pouches and other waste plastic containers composed of HDPE, PP and the like which have been segregated from the plastic waste were used for making granules which were used in preparing final product like pallets, interlocking tiles. These waste after segregation were washed and dried to remove the unwanted dirt and dust particles.

After drying these waste plastics, these are shredded into very small size pieces for better mixing in high-speed mixer and incorporation of the filler material into the waste plastic matrix. These shredded pieces of waste plastic are then mixed with different weight percentage loadings of rice husk ash and stearic acid coated calcium silicate along with micro sphere carbon beads to form blends which can be used in making different products for industrial applications.
7. Brief Description of the Drawings:
In the drawing accompanying the specification In the drawings accompanying the specification, Fig 1 is a schematic representation of waste plastic recycling and making granules and final products like pallets and interlocking tiles
In the drawings accompanying the specification, Fig 2 is electrostatic charge
dissipation of the composite tiles
In the drawing accompanying the specification, Fig 3 is Flammability test of the
waste plastic tile sample as per ASTM D-635-03 & IEC-60695-11-10 (a) and (b)
Specimens of waste plastic +MCMB (LM4) and waste plastic MCMB (LM5)
composite tiles respectively mounted on stand for measuring linear burning rate;
(c) linear burning rate of different samples
In the drawing accompanying the specification, table 1 gives Water absorption
and flammability levels with different weight percent loading of filler graphitized
MCMB in the waste plastic (L)matrix as per ASTM standards
8. The following examples are given to illustrate the process of the present
invention and should not be construed to limit the scope of the present
invention:
Example 1
Production of rice husk ash from rice husk
The rice husk collected from agriculture land producing rice was first washed in running water to remove unwanted dust particles attached to it followed by drying

in oven at about 100°C. For converting rice husk to rice husk ash, rice husk was heat treated at suitable temperature for a fixed time. The nature and type of rice husk ash produced depends on the nature of silica in it, silica can be amorphous or crystalline depending on the temperature it is exposed to and the time of exposure. For the purpose of using it as filler in making granules, amorphous silica is required because it is more reactive in comparison to crystalline silica. The rice husk after drying was crushed and grinded into a fine powder which was then heat treated at 700-800°C for about 4 hours in the muffle furnace. During the process, all the organic matter undergoes combustion and released in form of carbon dioxide leaving behind amorphous silica as a residue.
Example 2
Stearic acid coated calcium silicate
In a conical flask, 100 gms of stearic acid was dissolved in acetone and stirred for 1-2 hours till stearic acid is completely dissolved. To this, specific amount of calcium silicate in the ratio of 1:1 and 1:0.5 was added and the solution was continuously stirred for 4-6 hours and then solution was filtered and the resultant powder was dried in vacuum oven at 60°C till a fine powder is obtained. This mixture was then used for blending with waste plastic.
Example 3 Preparation of Micro carbon micro beads
Coal tar pitch (CTP) and Petroleum pitch (PP) are mixed in 1:1 ratio and grinded. The mixture was then transferred into a distillation assembly where the low molecular weight volatiles were removed by the distillation process and also the polymerization of some low molecular mass aromatics which can exhibit mesophase take place simultaneously at 320°C for about 2 hours. The mixture was then cooled to room temperature and transferred to a steel boat for drying. The pitch thus obtained is called Intermediate Pitch (IP). The Intermediate Pitch was then pyrolyzed at 400°C for 5 hours in inert atmosphere in furnace with a thermocouple to carry out further polymerization and removal of low molecular aromatics, the mixture was then cooled to room temperature. Micro carbon micro spheres are then

extracted from above mixture using quinoline and tar oil in 1:6 ratios, the mixture was then filtered and MCMB were separated after subsequent washings with toluene and acetone followed by calcinations at 320°C for 2 hours in N2 atmosphere. Finally, MCS obtained were semi-graphitized by heat-treating at 1400°C in inert atmosphere to obtain graphitized MCMB and called GMCMB.
Example 4
Fabrication of waste plastic granules by blending with rice husk ash
In a high-speed mixer, 600 gms of waste shredded poly propylene is mixed with 100 gms of shredded waste low-density polyethylene in which 100 gms of rice husk ash, 100 gms of stearic acid calcium silicate and 50 gms of MCMB are pre-mixed along with UV retardant and this was thoroughly mixed for 4 hour in the presence of lubricating medium. This mixture containing all constituents are then extruded in twin screw extruder so that the desired granules of specific sizes can be obtained. These granules are then used for making sample tile for density, flammability testing and tensile strength testing as per ASTM standards.
Example 5
In a second combination, 600 gms of waste shredded poly propylene is mixed with 100 gms of shredded LDPE are mixed in a high speed mixer alongwith 100 gms of rice husk ash, 50 gms of stearic acid calcium silicate, 50 gms of stearic acid coated magnesium hydroxide and 50 gms of MCMB and mixed thoroughly along with 50 gms of UV retardant for 4 hours along with lubricating medium so that the inorganic particles are thoroughly mixed along with waste plastic so that the mixture can be extruded in a twin screw extruder so that the wires coming from the screw can be cut in the cutter without any problem. The granules so obtained are then moulded into a square of 8 inches x 8 inches for testing the final product for its usage for making pallets and interlocking tiles.
Example 6

In another batch of experiment, 500 gms of PP are mixed with 100 gms of LDPE and taken along with 50 gms of a thermoplastic SEBS and mixed in a high-speed mixer alongwith 100 gms of rice husk ash and 200 gms of stearic acid coated calcium silicate alonwith 50 gms of MCMB along with 50 gms of UV retardant. The mixing was continued for 4 hours and then extruded with twin screw extruded and granules are obtained so that these granules can be tested for finding its application for end usage.
Example 7
In another combination, 600 gms of waste shredded poly propylene taken with 100 gms of shredded LDPE are mixed in a high speed mixer alongwith 100 gms of rice husk ash, 150 gms of stearic acid calcium silicate, 50 gms of stearic acid coated magnesium hydroxide and 50 gms of MCMB along with 50 gms of UV retardant and mixed thoroughly for 4 hours along with lubricating medium so that the inorganic particles are thoroughly mixed along with waste plastic so that the mixture can be extruded in a twin screw extruder so that the wires coming from the screw can be cut in the cutter without any problem. The granules so obtained are then moulded into a square of 8 inches x 8 inches for testing the final product for its usage for making pallets and interlocking tiles. 9. Advantages:
• Waste Plastic packaging material and plastic scrap made of Low-Density Polyethylene (LDPE), Linear low-density polyethylene (LLDPE), high density polyethylene, poly propylene is difficult to recycle though there is a possibility of recycling individual plastics.
• The present invention involves recycling of waste plastic packaging materials, milk pouches, polyethylene bags and other plastic scrap composed of poly olefins family blended with specific fillers from agriculture waste like rice husk ash, coal tar waste like microsphere carbon beads and in making granules which can be designed in making different products like pallets, interlock tiles which has different industrial and societal applications.

10. Claims
We Claim:
1. AN IMPROVED PROCESS FOR THE RECYCLING OF WASTE PLASTICS like LDPE, HDPE, PP and the like and by blending it with rice husk ash, mesocarbon microspheres, UV retardants and selective ratio of stearic acid coated calcium silicate and making granules which can be used in the making of pallets, interlocking tiles, floor tiles and the like.
2. AN IMPROVED PROCESS FOR THE RECYCLING OF WASTE PLASTICS as claimed in claim 1 wherein rice husk ash was prepared by heating rice husk, a waste byproduct of agriculture waste, in a muffle furnace at 600-800°C for 4-6 hours and characterizing the rice husk ash by XRD and Scanning electron microscope.
3. AN IMPROVED PROCESS FOR THE RECYCLING OF WASTE PLASTICS as claimed in claim 1, wherein MCMB was procured from the market for blending it with waste plastics.
4. AN FMPROVED PROCESS FOR THE RECYCLING OF WASTE PLASTICS AS CLAIMED IN CLAIM 1, wherein calcium silicate was coated with stearic acid for blending it with waste plastic.
5. AN FMPROVED PROCESS FOR THE RECYCLING OF WASTE PLASTICS AS CLAIMED IN CLAIM 1, wherein master batch of UV retardant was used as such available from the market.
6. AN IMPROVED PROCESS FOR THE RECYCLING OF WASTE
PLASTICS FOR THE RECYCLING OF WASTE PLASTICS AS
CLAIMED IN CLAFM 1, wherein specific ratios of waste plastic are
blended with various ratios of rice husk ash, MCMB, calcium silicate
coated with stearic acid and UV retardant.