The Development of Eco-Luxury Vinyl Plank (eLVP) Flooring: An Innovative Approach Using Recycled High-Density Polyethylene (rHDPE)

Plastics are now widely used materials in many commercial applications and play a significant role in our daily lives. However, one of the primary environmental issues in Malaysia is solid waste management and the emission of volatile organic compounds (VOC) into the air during the manufacturing of plastic products that contain polyvinyl chloride (PVC), especially in luxury vinyl plank (LVP) flooring production. The main goal of this research is to discuss the problems of plastic waste and propose innovation of LVP flooring using recycled HDPE (rHDPE). Thus, this paper review and discusses the components and materials of eco-luxury vinyl plank flooring (eLVP), the manufacturing process, and the market potential for eLVP flooring in the construction industry. eLVP offers new core structure materials using recycled High-Density Polyethylene (rHDPE) replaced PVC in the existing LVP flooring core structure. A simulation method through the application of Google SketchUp Pro 2021 to demonstrate the manufacturing process, enhanced the visual of the potential innovation product of eLVP flooring. The manufacturing process involved raw materials preparation; shredding and melting down the rHDPE; new product shaping and compacted process; resin applying process; wear layer and underlay process; and cutting process. The initiative to utilize rHDPE in this study intends to resolve global environmental and health issues because HDPE plastic is the most environmentally stable of all plastics, and it has widely used especially in food packaging. Recycling this plastic waste will assist to boost the economy by lowering production costs.