Crosslinked polyethylene (XLPE) is widely used in energy cables but is difficult to recycle due to its thermoset nature. As a result, thousands of tons of XLPE waste are landfilled annually. This study investigates a sustainable recycling strategy by mechanically reducing XLPE waste into powder and blending it with polypropylene (PP) to create an injection-moldable composite. An experimental matrix of blends was created to evaluate the effects of XLPE particle size and weight percentage on mechanical and rheological properties. Characterization techniques included tensile and impact testing, melt flow index, and oxidative induction time. Results show that XLPE content significantly affects flow behavior, while particle size plays a larger role in mechanical performance. Optimized blends demonstrated suitable properties for use in non-electrical applications such as cable spool manufacturing. This approach presents a potential avenue for large-scale reuse of XLPE scrap in the wire and cable industry.
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