Particleboard Manufacturing Research Articles

Life cycle assessment of a hot-pressing machine to manufacture particleboards: hotspots, environmental indicators, and solutions

Green manufacturing (GM) is the environmental benign manufacturing of products with a minimal negative impact on the natural environment. Research studies on GM have increased in the last years with attention to the application of life cycle assessment (LCA). However, the manufacturing industry still faces some barriers and challenges that hinder a proper practical integration of GM using LCA. Accordingly, this paper performs an LCA-based GM case study of a wood-based industry that produces particleboards to investigate environmental hotspots and suggests GM indicators and solutions for a hot-pressing machine tool. A case study of a wood-based industry that produces particleboards in Brazil was designed. A LCA-based GM framework was developed and applied according to its three phases: pre-assessment, environmental assessment and monitoring, and post-assessment. Each phase is composed of specific stages and each stage has its own activities and goals. To quantify the environmental life cycle impacts, the ILCD midpoint method with 13 impact categories was selected. Based on these environmental impacts, a set of indicators and solutions was designed to improve the product life cycle impacts through a greener manufacturing process of particleboards. A cradle-to-grave approach was used to model the particleboard life cycle and the manufacturing phase was modeled based on the unit process life cycle inventory (UPLCI) methodology. The particleboard manufacture was designed into five unit processes and results of the pre-assessment showed that the hot-pressing unit was the most relevant process because of its direct and indirect impacts mainly to human toxicity cancer effects, global warming, and photochemical ozone formation. During the environmental assessment and monitoring phase, the hot-pressing machine was then investigated based on the main contributors to the caused environmental impacts, i.e., electricity consumption and air emissions of free formaldehyde, as well as in terms of its most relevant process parameters: pressure (P) and temperature (T). Opportunities to reduce up to 21% upstream impacts and up to 41% downstream impacts were identified from making simple changes to the hot-pressing parameters. Further investigation in the post-assessment revealed that environmental impacts can be estimated based on the applied P and T values and GM indicators were suggested. The proposed GM framework can be used in other case studies to integrate GM + LCA in practice. Results of the case study application showed that the hot-pressing machine was a hotspot into the cradle-to-grave life cycle impacts of particleboards and the proposed GM indicators can be used to predict life cycle impacts at manufacturing level.

Utilization of Cassava Maltodextrin for Eco-friendly Adhesive in the Manufacturing of Sorghum Bagasse Particleboard

The development of natural adhesives derived from non-fossil resources is very important for the future. This research aimed to develop natural adhesive from maltodextrin and compare it with other natural adhesives such as citric acid and malic acid for particleboard production. The effect of the adhesive raw materials on the physical and mechanical properties of the particleboards was investigated. The sweet sorghum and those natural adhesives were used in the manufacturing of particleboard. The resin content of the natural adhesive was 20 wt% base on air-dried particles. The dimension and density target of the boards were 30 x 30 x 0,9 cm3 and 0,8 g/cm3, respectively. The particleboards were prepared by hot pressing at 200°C for 10 min. The physical and mechanical properties of particleboards were evaluated based on Japanese Industrial Standard for particleboard (JIS A 5908-2003). The results showed that the density, moisture content, modulus of elasticity, and modulus of rupture met the requirements of the JIS A 5908-2003 standard, while the thickness swelling, water absorption, and internal bond did not meet the standard requirements. The results of FTIR analysis indicated the establishment of ester linkages due to the reaction between the natural adhesive and sorghum bagasse that contributed to the excellent physical and mechanical properties of the particleboard.Keywords: cassava, maltodextrin, natural adhesive, particleboard, sweet sorghum

By-products of sawmill industry as raw materials for manufacture of chip-sawdust boards

The paper investigated the possibility of using sawmill industry by-products, i.e. chips and sawdust as raw materials for the production of building wood-based boards. We prepared three-ply boards with the outer layer made from two types of pine particles (A and B) with different dimensions, and the core layer containing a mixture of chips and sawdust at 70 : 30 or 60 : 40 wt ratio. The boards also featured different core layer (CL) to outer layers (OL) ratio of 70 : 30 or 60 : 40. The study demonstrated that unprocessed by-products of mechanical woodworking in the form of chips and sawdust are valuable raw materials for the production of wood-based boards. Irrespective of CL : OL ratio, the boards with the best properties were those with outer layers made of microparticles larger than the ones used currently in particleboard manufacture and with core layers containing 70% of chips. The highest bending strength, modulus of elasticity and dimensional stability of board was noted for CL : OL ratio of 60 : 40, while the highest internal bond was achieved for CL : OL ratio of 70 : 30. These boards may be used as non-structural elements intended for construction industry and interior decoration.

Characteristics of Bamboo Particleboard Bonded with Citric Acid-Starch Using Three-Step Press Cycle Method

In an attempt to reduce the use of a formaldehyde-based adhesive that is dangerous for both human health and environment, several studies had been done to develop particleboard with natural bio-based adhesives. Between those bio-based adhesives that have been investigated, the combination of citric acid-starch was potential to be developed further as an adhesive to particleboard. In this research, the effect of starch addition and press temperature on the properties of bamboo particleboard were evaluated. This research uses a combination of citric acid/starch with the composition weight ratio of 100/0, 90/10, 80/20 and 70/30 and press temperature of 160, 180 and 200 °C. The manufacture of particleboard also used a three-step press cycle method which has not been done before in Petung bamboo particleboard production. The result showed that the three-press cycle method used in this research was able to produce a board with excellent properties than board produced by single-step press cycle method. This showed that the manufacture of the board in this research was more efficient to produce citric acid-starch bonded particleboard than previous method being used. The results also showed that both the addition of starch and the increase of press temperature especially improved bamboo particleboard mechanical properties. The board with the optimum properties resulted from particleboard with citric acid/starch adhesive with the composition weight ratio of 80/20 and press temperature of 180 °C which could meet JIS A 5908 (2003) type 18 requirement.

Greener adhesives based on UF/soy protein reinforced with montmorillonite clay for wood particleboard

AbstractThere is a global concern about the types of adhesives used for the binding of wood particles, most of which include formaldehyde in their formulation. The aim of this work is to study the effect of raw montmorillonite (Mt) particles on blended urea formaldehyde (UF)/soy protein (SP) adhesives for the manufacture of wood particleboards to reduce the use of this carcinogenic component. Rheology showed that Mt does not alter the viscosity of adhesives at high shear rates, so they can be applied by spray. Thermogravimetric analysis/derivative thermogravimetry (TGA/DTG) analysis revealed an enhancement of their thermal stability due to the presence of clay particles. Polymer–Mt interaction was studied by small amplitude X‐ray scattering and scanning electron microscopy. According to these results, the exfoliated structure of the clay particles was achieved. Wood particleboards were manufactured with UF/SP/Mt adhesives in order to study their mechanical properties. The three‐point bending test showed that Mt particles improved the modulus of both rupture and elasticity. UF/SP/Mt resins proved to be a prominent product for the development of environmentally friendlier particleboards with desirable mechanical properties.

Mechanical analysis of bamboo and agro-industrial residue one-layer particleboard

A high-density particleboard composed of peanut shells (Arachis hypogaea L.), an agro-industrial residue, and bamboo wastes of the species Dendrocalamus giganteus (branches and apical part), bonded with a two-component polyurethane resin based on castor oil (Ricinus communis L.) in the proportion of 12% of the particleboard mass, was produced. Four types of specimens were prepared according to the percentage of peanut shells: 0%, 10%, 20%, and 30%. Mechanical characteristics were evaluated through the flexural strength tests for modulus of rupture, modulus of elasticity, perpendicular traction, and screw pull resistance. The particleboard reached an average density of 917.2 kg/m3, meaning that it could be classified as high-density particleboard. The results of the mechanical tests indicated that the specimens containing a mixture in the proportion of 90% bamboo and 10% peanut hull presented the best mechanical strength. The experiment produced particleboards with a satisfactory mechanical physical performance that met the standards ABNT NBR 14.810-2 and ANSI A208-1, supporting the use of the peanut shell residue in the manufacture of particleboards to be used in internal environments and allowing the applicability of this residue through additional value.

The Physical, Mechanical, and Sound Absorption Properties of Sandwich Particleboard (SPb)

While the utilization of wood as a raw material in related industries has been increasing with the population increasing, the availability of wood from natural forests has continued to decline. An alternative to this situation is the manufacture of particleboard from non-wood lignocellulose materials through the modification of sandwich particleboard (SPb) using bamboo strands as reinforcement. In this study, strandsof belangke bamboo (Gigantochloa pruriens W) and tali bamboo (Gigantochloa apus) were utilized. The non-wood particles included sugar palm fibers, cornstalk, and sugarcane bagasse. The board was made in a three-layer composition of the face, back, and core in a ratio of 1: 2: 1. The binder used was 8% isocyanate resin. The sheet was pressed at a temperature of 160°C for 5 min under a pressure of 3.0 N/mm2. Testing included physical and mechanical properties based on the JIS A 5908 (2003) standard, while acoustic testing was based on ISO 11654 (1997) standards. The results showed that using bamboo strands as reinforcement has an effect on the mechanical and physical properties of SPb. Almost all the types of boards met the JIS A 5908 (2003) standards, with the exception of thickness swelling (TS) and internal bond (IB) parameters. Based on the thickness swelling parameter, the C-type board exhibited the best properties. Overall, the B-type board thatused a belangke bamboo strand for the surface and sugarcane bagasse as the core underwent the best treatment. Based on the acoustical parameter, boards using a tali bamboo strand for the surface and sugar palm fiber as the core (E-type board) exhibited good sound absorption properties.

Increasing Cold Tack of Polymeric Methylene Diphenyl Diisocyanate Resin with Partial Soy Flour Substitution

Abstract Partial substitution of polymeric methylene diphenyl diisocyanate resin with soy flour increases the cold tack of the resin to the level achieved by urea formaldehyde resin. The tack can be fine-tuned by adjusting the amount of soy flour added. The increase in tack is caused by the reaction of the isocyanate resin with the water contained in soy flour, as well as with hydroxyl and other groups present in soy flour components. The higher cold tack should increase the stability of pre-press mats, especially in particleboard manufacturing.

Incorporation of water treatment plant sludge in wood-based particleboard manufacturing

Incorporation of water treatment plant sludge in wood-based particleboard manufacturing

Characterization of Particleboard Produced from Residues of <i>Plantain pseudostem</i>, Cocoa Pod and Stem and <i>Ceiba</i>

This study investigated the possible use of four agro-forest residues generated in Ghana as an alternative raw material for particleboard manufacture using cassava starch and urea formaldehyde as adhesives. The particle size of the materials ranged from 0.5 mm to 1.5 mm. An industrial pressing machine was used to press the homogeneous single layer particleboard. Physical and mechanical properties were determined in accordance with ASTM D 1037-06a and ASTM D 7519-11. The results indicate that the density of the particleboards produced ranged from 421 kg/m3 to 598 kg/m3. The water absorption property of the particleboards also ranged from 7.66% to 22.41% and 18.17% to 59.46% for 2-hour and 24-hour immersions respectively. Additionally, the thickness swelling of the particleboards ranged from 3.38% to 5.03% and 9.37% to 21.49% for 2-hour, and 24-hour immersions respectively. The results further indicate that the modulus of elasticity, modulus of rupture, internal bond strength and hardness of the particleboards produced for both cassava starch and urea formaldehyde were adequate. Comparatively, for all the agro-forest materials used for this study, the physical and mechanical properties of the particleboards produced using urea formaldehyde as adhesive was better than those produced using cassava starch as adhesive. It could be concluded that the particleboards produced could be used for indoor applications or interior furnishings, under dry conditions. Additionally, it is recommended that further studies that combine cassava starch and urea formaldehyde as adhesives be conducted, as well as studies on combining plantain pseudostem and cocoa pod in particleboard production.

INFLUENCE OF RESIDUE TYPE ON QUALITY PROPERTIES OF PARTICLEBOARD MANUFACTURED FROM FAST-GROWN TREE OF HEAVEN (Ailanthus altissima (Mill.) Swingle)

INFLUENCE OF RESIDUE TYPE ON QUALITY PROPERTIES OF PARTICLEBOARD MANUFACTURED FROM FAST-GROWN TREE OF HEAVEN (Ailanthus altissima (Mill.) Swingle)

Characterization of rubberwood particleboard made using carboxymethyl starch mixed with polyvinyl alcohol as adhesive

The aim of the study was to produce and characterize the modified starches and their suitability as wood adhesive for the particleboard manufacturing. The adhesive properties and particleboard manufactured from rubberwood using the modified starch and modified starch mixed with polyvinyl alcohol (PVA) were evaluated. Mixing of PVA with modified starch reduced the viscosity but increased the solid content and thermal property of the modified starch. Particleboard bonded with modified starch mixed with PVA also had improvement in physical and mechanical properties, showing great potential of modified starch and PVA as an adhesive for the green particleboard with good properties.

Manufacture of thin rice straw particleboards bonded with various polymeric methane diphenyl diisocyanate/ urea formaldehyde resin mixtures

Reducing particleboard thickness is one of the major approaches to decrease consumption volume of particleboard for furniture manufacture. This study employed an adhesive mixture of polymeric methane diphenyl diisocyanate (PMDI) and urea formaldehyde (UF) to produce single-layer medium density thin rice straw particleboard. The effects of various PMDI/UF formulations as well as board density on mechanical properties and water resistance of rice straw particleboard were studied. The results indicated that the mechanical properties and water resistance of the thin rice straw particleboard were appreciably affected by resin formulation. The panels bonded with PMDI/UF adhesive mixtures had mechanical properties and water resistance far superior to those bonded with UF. Higher PMDI content levels in resin mixtures led to improved mechanical properties and water resistance. Density influenced mechanical properties and water resistance of the thin rice straw particleboard. Increasing the density of the panel could upgrade the mechanical properties of the thin rice straw particleboard. The experimental outcomes showed that PMDI/UF resin systems had potential to substitute for pure PMDI resin in producing thin rice straw particleboard, which could effectively lower manufacturing cost and bring economic efficiencies due to reduced amount of pricey PMDI.

Properties of Particleboard from Sawmill Wastes and Rubberwood (Hevea brasiliensis) with Different Board Thickness and Resin Content

This study investigate the effect of the board thickness and resin content on the properties of particleboard. Single-layered sawmill wastes and rubberwood particleboards bonded with urea formaldehyde (UF) resins were manufactured. The boards were fabricated with three different board thicknesses (15, 18 and 25mm) at three different resin contents (7, 8 and 9%). The boards produced were evaluated for their modulus of elasticity (MOE), modulus of rupture (MOR), internal bonding (IB) and thickness swelling (TS) in accordance with the European Standards. Board thickness does affect the mechanical properties of particleboard. The study revealed that thinner boards gave higher MOE, MOR, IB and TS. No significant effects were found among three resin contents for MOE, MOR, IB and TS. It can be concluded that the particleboard made from mix tropical wood from sawmill waste and with rubberwood were suitable for particleboard manufacturing.

Further Exploration of Sucrose-Citric Acid Adhesive: Synthesis and Application on Plywood.

The development of eco-friendly adhesives is a major research direction in the wood-based material industry. Previous research has already demonstrated the mixture of sucrose and citric acid could be utilized as an adhesive for the manufacture of particleboard. Herein, based on the chemical characteristics of sucrose, a synthesized sucrose-citric acid (SC) adhesive was prepared, featuring suitable viscosity and high solid content. The investigation of synthesis conditions on the bond performance showed that the optimal mass proportion between sucrose and citric acid was 25/75, the synthesis temperature was 100 °C, and the synthesis time was 2 h. The wet shear strength of the plywood bonded with SC adhesive, which was synthesized at optimal conditions and satisfied the China National Standard GB/T 9846-2015. The synthesis mechanism was studied by both 13C NMR analysis and HPLC, and the chemical composition manifesting caramelization reaction occurred during the synthesis process. The results of ATR FT-IR indicated the formation of a furan ring, carbonyl, and ether groups in the cured insoluble matter of the SC adhesive, which indicated dehydration condensation as the reaction mechanism between sucrose and citric acid.

Physical and mechanical properties of urea formaldehyde and phenol formaldehyde-bonded particleboards made from corn stalk

Biomass from annual fibers and agricultural wastes as a raw material to produce particleboard or other composite panels has gained increased popularity. The purpose of this study was to investigate the suitability of corn stalk as a material for particleboard manufacturing. The effect of adhesive type and concentration on the physical and mechanical properties of particleboard manufactured from corn stalk was evaluated. Particleboards were produced using hot-pressing machine at temperature of 130 °C for urea formaldehyde (UF) and 150 °C for phenol formaldehyde (PF) adhesives until 10 min. The size of particleboards and target density were 25 mm x 25 mm x 0.9 mm and 0.8 g/cm3, respectively. The adhesive content was varied from 8, 10 and 12 wt%. The results showed that the physical and mechanical properties of particleboards had better values with increasing the adhesive concentration. The board bonded with PF adhesive showed better physical and mechanical properties than the board bonded with UF adhesive. The modulus of rupture, modulus of elasticity and internal bond of the board bonded with 12 wt% of PF fulfilled the requirement of the JIS A 5908 (2003) for type 13 particleboard.

KUALITAS PAPAN PARTIKEL DARI LIMBAH GERGAJIAN KAYU BANGKIRAI (Shorea laevis Ridl) (Quality of Particle Board From Saw Waste Wood of Bangkirai (Shorea laevis Ridl))

ABSTRACTThe particle board is a wood product resulting from the heat-blowing process between a woodparticle mixture or lignocellulosic raw material with an adhesive or a wood product ofreconstitution. A research on particle board manufacture was conducted using Bangkirai woodparticles bonded together with urea formaldehide (UF) adhesive. This research aimed todetermine the quality of particle board produced on its physical and mechanical properties.Particle particle size is 30 cm x 30 cm x 1 cm with target density 0,7 g / cm3. Results revealedthat UF adhesive level had an effect on moisture content, density, water absorption, thicknessswelling, MoR, MoE and screw-withdrawal strength. Density and thickness swelling that couldfavor the Japanese standards either partially or completely. Based on the value of density,particle board of this experimental results is more suitable for use as a room divider andfurniture raw materials. Particle board with 25% adhesive content provides a good prospect inthe particle board manufacturing industry.Keywords: Particleboard; physical and mechanical properties; Bangkirai wood; UreaFormaldehyde adhesive

Sugar beet pulp as raw material for particleboard production

Increasing demand for production of particleboard and environmental concerns drive to seek new sources of lignocellulosic materials other than wood. Sugar beet pulp (SBP) is one of the most common agro-residues, which remains after sugar production. Conducted investigation was to determine the suitability of SBP as a raw material for particleboard manufacturing. Three-layer particleboards with the core layer made of mixture SBP and industrial wood particles were prepared. Tested particleboards varied in proportions of SBP and wood particles used for the core layer. Investigation included following physical and mechanical parameters of boards: density and density profile, thickness swelling (TS), water absorption (WA), modulus of rupture (MOR), modulus of elasticity (MOE), internal bond (IB) and screw holding (SH). The results indicated negative impact of high content SBP on the board properties. Particleboards containing up to 30% SBP exceed the minimal requirements for MOR and MOE set in the European standards, for boards for interior fitments (including furniture) for use in dry conditions. The WA and TS values for that variant were similar to control particleboard. All of the particleboards produced with shear of SBP particles in core had higher IB than required.

COMPRESSIVE RESISTANCE OF THE MYCELIUM COMPOSITE

Compressive resistance of the mycelium composite. Mycelium composites are a type of novel, economical and environmentally sustainable materials. The advantage of this material is that it forms a compact unit without the use of any adhesives. In this study mycelium boards were prepared from middle wood chipped particles for the manufacturing of commercial particle boards by using the growth activity of fungus Trametes versicolor. The compressive resistance of the mycelium composite was low but acceptable and comparable with other materials.

High-performance binderless particleboard from the inner part of oil palm trunk by addition of ammonium dihydrogen phosphate

The inner part (i.e., two-thirds of the diameter) of oil palm trunk (OPT) generally becomes waste because of its insufficient properties (e.g., low strength, low durability). Herein we attempted to use the inner part of OPT as a raw material of binderless particleboard in order to change this waste into an environmentally friendly value-added product. In this study, ammonium dihydrogen phosphate (ADP) was used as an additive, and the effect of ADP additions on the properties of particleboard manufacturing using the inner part of OPT was investigated. The ADP additions were varied from 0 to 40 wt%. First, thermal analyses were conducted to clarify the effect of ADP addition on the thermal properties of the OPT, and it was observed that the thermal properties of the OPT were significantly lowered with the increase in ADP additions. Based on these results, particleboards with a target density of 0.8 g/cm3 were manufactured under the pressing condition of 180 °C for 10 min. The physical and mechanical properties of the particleboards were improved with the addition of ADP until 10 wt%. The water resistance was also significantly improved. It was suggested that part of the water-soluble components of OPT particles would change to water-insoluble components by the addition of ADP. Our findings demonstrate that the addition of ADP was effective for improving the physical and mechanical properties of particleboard using the inner part of OPT.