Sustainable Conversion of Expanded Polystyrene Waste into Nonwoven Fabric Using the Melt Jet Spinning Process: Characterization and Properties

Abstract

Expanded polystyrene (EPS) is commonly used in everyday life for packaging, construction materials, and household appliances. However, EPS waste contributes significantly to environmental pollution due to its nonbiodegradable nature. To address this issue, the utilizing EPS waste to produce nonwoven fabric has been explored as a potential recycling solution to reduce its environmental impact. In this study, EPS waste was dissolved in acetone as a solvent to facilitate degassing, after which the solvent was evaporated. The remaining material was ground into smaller particles and formed into fibers using varying air pressures (0.2–0.5 psi) in the melt jet spinning process. The fibers were subsequently compressed into specimens through hot-pressing for testing. The results showed that higher air pressures produced finer fibers, which significantly improved thermal conductivity and penetration resistance, while air permeability decreased. Thermal properties exhibited minor changes without a clear trend. This research highlights the potential of utilizing recycled EPS waste for applications such as filters, ceiling panels and soilless farming materials, contributing to sustainable waste management practices.