Polymer recyclate processes and products

A method for processing low density polyethylene (LDPE) recyclate comprising:

• a. providing a LDPE recyclate feedstock having:
• i) a first density in the range of from 0.910 g/cm3 to 0.940 g/cm3;
• ii) a first melt index (12;
• 2.16 kg, 190° C.) less than or equal to 5.0 g/10 min;
• iii) a first molecular weight distribution (Mw/Mn) greater than 4.0;
• iv) a first weight average molecular weight (“Mw1”) greater than or equal to 85,000 daltons;
• and
• v) a first melt elasticity (“ER”) greater than or equal to 1.0;
• b. adding the LDPE recyclate to a first extruder to produce a first LDPE recyclate melt;
• c. subjecting the first LDPE recyclate melt to visbreaking conditions to produce a second LDPE recyclate melt having:
• i) a second density, wherein the ratio of the second density to the first density is greater than or equal to 1.0;
• ii) a second melt index, wherein the ratio of the second melt index to the first melt index is greater than or equal to 5.0;
• iii) a second molecular weight distribution, wherein the ratio of second molecular weight distribution to the first molecular weight distribution is in the range of from 0.60 to 0.99;
• iv) a second weight average molecular weight (“Mw2”), wherein Mw2/Mw1 is in the range of from 0.60 to 0.99;
• and
• v) a second melt elasticity, wherein the ratio of the second melt elasticity to the first melt elasticity is in the range of 0.30 to 0.90;
• wherein a LDPE recyclate product is formed by withdrawal of the second LDPE recyclate melt from the first extruder, and further processing or pelletizing of the second LDPE recyclate melt
• d. adding the LDPE recyclate product and a first polyolefin blend component to a second extruder;
• and
• e. effecting compounding conditions in the second extruder to form a polyolefin product comprising the melt-blended mixture of the LDPE recyclate product and the first polyolefin blend component.