Particleboard Production Research Articles

Leveraging Spruce Bark Particle Morphology for Enhanced Internal Bonding in Particleboard Production.

The continuous rise in global demand for wood products has led to an increase in prices and a surge in research into alternative resources. As a byproduct of the timber industry, bark has emerged as a promising supplement in particleboard (PB) production. However, its anatomical structure, the presence of extractives, and its inferior mechanical properties complicate the production process, which have not yet been fully overcome at a commercial scale. This study proposes a paradigm shift, advocating for separate and specialized bark constituent processing in a wet state. Three bark-based raw materials-namely, outer bark particles, bark fiber clumps, and bark fibers-were investigated under varying wood content scenarios. PBs with a target density of 0.7 g/cm3 and a thickness of 16 mm were produced using mixtures of these bark-based materials and wood particles in different ratios bonded with a urea-formaldehyde adhesive. The results demonstrated that these bark constituents exhibit distinct properties that can be optimized through tailored processing techniques. Compared to bark fibers, outer bark particles displayed about 40% lower water absorption and thickness swelling. However, bark fibers improved the internal bond by about 50% due to their favorable morphology compared to outer bark. These findings highlight the potential of bark as a valuable resource for particleboard production and pave the way for its efficient utilization through specialized processing strategies.

The effect of urea-formaldehyde adhesive modification with diisocyanate-functionalized nanocellulose on the properties of particleboard

In this paper, a nanocrystalline cellulose (NCC) functionalized with 4,4′-diphenylmethane diisocyanate (MDI) was used as a modifier for urea-formaldehyde (UF) adhesive in particleboard production. The applied method of NCC functionalization with diisocyanate has not been previously studied in research on wood-based materials. Chemical structure of MDI-NCC evaluated with Fourier transform infrared spectroscopy (FTIR) demonstrated some significant changes indicating that the functionalization was effective. No change in crystallinity caused by the modification was noted based on the lateral order index and total crystallinity index. Hydrophilicity of NCC was reduced due to the functionalization with MDI. Based on the differential scanning calorimetry (DSC) results, it was found that the reactivity of the resin was improved by the addition of NCC, and moreover, the effect was even more noticeable when the MDI-NCC was introduced. Properties of manufactured particleboards such as density, water absorption and formaldehyde content were not affected by the resin reinforcement. In turn, the modification of NCC with MDI allowed to increase the strength and reduce swelling of the particleboards more significantly than in the case of a neat NCC. It indicates that application of diisocyanate-functionalized NCC has great potential for the use as the UF resin modifier in particleboard production.

Optimization of mixing ratio for the production of particle board from bamboo leaves, saw dust and urea formaldehyde

This study investigated the best mix sawdust, bamboo leaves, and urea formaldehyde to create particleboard by optimizing the mixing ratio. Finding the optimal ratio of sawdust, urea formaldehyde, and bamboo leaves for the binders used in particle board production was the aim of this study. The particle boards' mechanical and physical tests were investigated. The surface morphology of particleboards and its elemental compositions were examined using Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDS). The result observed from mechanical and physical tests conducted particle boards showed that best particleboard of composition 100 % sawdust, 50 % bamboo leaves and 2.5 g urea had the highest density of 675.643 kg/m3, modulus rupture of 3.84 N/mm2 and modulus elasticity of 2756 N/mm2. The optimal level generated by the experimental design of composition 50 % sawdust, 50 % bamboo leaves and 2.0 g urea were validated. MOR of 13.02 N/mm2 and MOE observed were 881.39 N/mm2. The SEM and EDS results revealed that optimal particleboard of validated experiment had surface with more fibrous network structures than particle board of the best process level. The particleboard that was produced from validated experiment complied with the American National Standard ANSI/A208.1–999.

Material properties of particleboards produced from Ciol®-treated wood shavings

ABSTRACT This study investigated the potential of wood particles from Ciol®-treated wood in particleboard production. Ciol® is a renewable formulation from water, citric acid, and sorbitol, which has been commercially developed as a promising alternative for wood modification. Radiata pine wood was impregnated with 60% and 85% concentrations of the Ciol® solution for 150 mins. The impregnated boards were cured and subsequently planned. Particleboards were thereafter produced from the wood shavings using urea formaldehyde (UF) and melamine urea formaldehyde resin (MUF). The boards were produced with or without the use of ammonium nitrate as a hardener. The wood particles and produced boards were characterized via analytical techniques and standard test methods. The effect of Ciol® treatment and its concentration on the properties of the shavings and the particleboards was investigated as well as the effect of the resin type on the panel properties. The use of MUF without the hardener gave the best bending strength of 13 N/mm² and modulus of elasticity of 3187 N/mm². However, there was no significant difference in the results obtained when the hardener was added to MUF resins. Recycling Ciol®-treated wood shavings in particleboard production proved to be a promising approach with MUF resins.

Life cycle assessment as a circular economy strategy to select eco-efficient raw materials for particleboard production

Life Cycle Assessment (LCA) is applied for choosing and comparing circular alternatives, comprising a bicomponent polyurethane resin based on castor oil (PU) and sugarcane bagasse (SB) particles to conventional materials using urea formaldehyde (UF) and eucalyptus particles, for the production of 1 m3 of medium-density particleboard (MDP), from cradle-to-gate, with five different formulations. Databases were used in life cycle inventory and the ReCiPe impact method was selected at midpoint level. The eco-efficiency index, based on modulus of rupture and CO2 emissions, revealed that the best condition was the panels using alternative materials, as it can reduce up to 74 % the environmental burdens investigated. The panel using only circular materials showed feasible technical performance according with the physical-mechanical properties considered, generating the best eco-efficiency indicator (0,154 MPa/CO2 eq.). These results build a foundation for reconsidering the selection of raw materials in large-scale MDP production, potentially leading to the adoption of more sustainable practices.

Studies on particleboard production using Expanded Polystyrene (EPS) waste as a binder for construction applications

This study explored the potential of using EPS waste as a substitute for synthetic resin in particleboard production. The objectives were to assess the impact of various processing parameters, including board density, EPS waste percentage, and pressing temperature, on the properties of the board. For this purpose, lab-scale particleboards were fabricated by combining kelempayan wood particles with EPS waste powders. Subsequently, the physical, mechanical, and thermal stability properties of the board were assessed. The results indicated that the board density, EPS waste percentage, and pressing temperature influenced the physical, mechanical, and thermal stability properties of the board. The bending properties, internal bond (IB) strength, and thickness swelling (TS) of the board exhibited an upward trend with increasing board density. At the same time, the TS decreased while bending properties and IB strength increased with rising EPS waste percentages and pressing temperatures. Notably, the board fabricated with a target density of 0.70 g/cm3, comprising 20 % EPS waste and pressed at 180°C, met the standard requirements for particleboard designated for construction purposes, except the modulus of rupture (MOR), which is slightly lower than the standard requirement. In addition, the thermal stability of the board increased with higher pressing temperatures. Conversely, increasing the density and EPS waste percentage to 40 % appeared to decrease the thermal stability of the board. These findings underscore the significant potential of EPS waste as a binder in particleboard production.

Optimizing paper sludge content and particle size to enhance particleboard properties

The pulp and paper industry generates vast quantities of paper sludge, posing significant environmental challenges due to its disposal in landfills or incineration. This study explores the potential of valorizing paper sludge by incorporating it into particleboard production. It aims to optimize sludge content and particle size to enhance board properties—a novel approach to waste management in the wood composites industry. Through systematic variation of sludge content (0–25%) and particle size (< 0.5 to > 2 mm), we assessed the mechanical and physical properties such as internal bond strength (IB), modulus of rupture (MOR), modulus of elasticity (MOE), water absorption (WA), and thickness swelling (TS). The findings indicate that incorporating paper sludge at moderate levels (5–15%) with optimized particle sizes (< 1 mm) significantly improves the mechanical properties of the particleboard, including increased IB, MOR, and MOE while reducing WA and TS. Principal Component Analysis (PCA) further supported these results, revealing that higher-density boards with enhanced mechanical properties absorb less water, highlighting the interrelationship between structural integrity and moisture resistance. The PCA also identified thickness swelling as an independent factor, suggesting that while mechanical properties can be optimized, additional strategies are needed to control swelling. In conclusion, this study demonstrates that up to 15% paper sludge can be effectively used in particleboard production without compromising quality, provided particle size is carefully controlled. This approach not only offers a sustainable solution for managing paper sludge but also contributes to the development of eco-friendly composite materials, aligning with circular economy principles.

PRODUCTION OF PARTICLEBOARD PANELS FROM WOOD OF Ochroma pyramidale

The objective of this work was to evaluate the use of the species O. pyramidale for the production of particleboards. The trees, aged 6 years, came from the Municipality of Mira Estrela/SP state. The logs were peeled and processed in an industrial chopper to obtain particles. Eight treatments were carried out, varying the levels of paraffin emulsion (0, 1, 1.5 and 2%), and the levels of urea formaldehyde adhesives (10 and 12%). The particles went through a drying process until they reached 4% moisture. For pressing the panels, the parameters temperature of 160°C, specific pressure of 30 kgf/cm² and time of 10 minutes were used. The panels were tested by physical tests and mechanical tests, all following the procedures of the following standards: D-1037 (ASTM, 2006) for density, water determination and thickness increase and internal connection; DIN 52362 (1982) for parallel static bending. As a result, it was concluded that the increased addition of paraffin to the panels resulted in an improvement in their dimensional stability. The treatment that added 12% urea formaldehyde adhesive and 1.5% paraffin achieved superior results in mechanical properties, equivalent to 10390.91kgf cm-2 for the separation modulus, 101.46kgf cm-2 for the rupture modulus. The O. pyramidale particleboards reached the minimum values of 1.4 kgf/cm² for internal bonding and 56 kgf/cm² for the modulus of rupture required by CS 235-66 (1968), thus becoming a potential species for the production of particleboard panels.

Suitability of thermally modified wood for binderless particleboard production: Effects of temperature and moisture content in hot pressing

The use of thermally modified wood has grown significantly worldwide over the past 20 years owing to its natural, chemical-free properties, enhanced dimensional stability, and improved biological durability. The binderless particleboard (BP) production process offers an effective way to recycle waste from thermally modified wood. In this study, Fourier-transform infrared (FTIR) spectroscopy and modulated temperature technology were employed to investigate the chemical changes in thermally modified wood as a function of temperature. The impact of moisture content (MC) and temperature on the compression characteristics of particleboards was also examined. The resulting particleboards were subjected to tests for thickness swell and structural morphology (SEM) and vertical density profile analyses. The particleboards produced from thermally modified wood with an MC of 20 % and at a hot-pressing temperature of 170 °C exhibited superior properties to those produced at 8 % MC and 150 and 190 °C. This superior performance can be attributed to the chemical changes in wood, particle size, and the heat transfer and conductivity of the particleboards at high temperature and MC, which renders them more malleable during hot pressing. The particleboards manufactured at 20 % MC and at a hot-pressing temperature of 170 °C demonstrated an internal bonding (IB) of 0.77 MPa, a thickness swell (TS) of 8.14 %, and a homogeneous density distribution. The study provides valuable insights into the production of particleboards from thermally modified wood by optimising the MC and temperature conditions for hot pressing. This research offers a sustainable approach to reusing thermally modified wood waste and promotes the development of more efficient particleboard production processes. Future research could focus on broadening the application scope and exploring the long-term durability and performance of the particleboards produced under the identified optimal conditions.

Shredded waste office paper as a component with wood particles in the production of particleboard

Shredded waste office paper as a component with wood particles in the production of particleboard

Wood Waste Recycling in Sweden—Industrial, Environmental, Social, and Economic Challenges and Benefits

The disposal of wood waste at facilities for incineration in Sweden is the only applied management practice today. Energy production from biomass has gained attention for its potential to recover energy and reduce greenhouse gas emissions. However, besides being a valuable source for energy generation, wood waste can be effectively recycled into new products. Specifically, recycling wood waste into particleboard is the widely practiced method in Europe, while its benefits have not been explored in the country so far. The objective of this study is to assess the environmental, social, and economic sustainability of producing particleboard and generating energy from wood waste in Sweden. This research investigates four alternative systems for wood waste disposal. The first system involves the production of heat, the second system involves heat and power by wood waste, while the third and the fourth systems, in addition to energy recovery, include partial recycling of wood waste in particleboard production. A life cycle sustainability assessment covering all three pillars (environment, social, and economic) of sustainability was conducted to compare these systems. The results show that adding recycling schemes to incineration in wood waste management practices strengthens the sustainability for all three aspects, and hence, these management methods can be considered as complementary methods rather than competing methods. When all sustainability categories are considered, alternative three (heat recovery and recycling) comes forward as the best option in 11 out of 16 impact categories.

Novel kraft-lignin-based adhesives for the production of particleboards

Lignin is produced worldwide in pulp mills and is currently mainly used for energy recovery. Because of its chemical properties, one possible utilisation is the production of lignin-based materials. Currently, developed lignin-based adhesives are based mainly on lignosulfonate instead of kraft lignin since lignosulfonate is more reactive than kraft lignin. However, worldwide substantially more kraft lignin is produced. The presented research deals with the development of resin chemically modified with kraft lignin up to 40% (w/w) content of kraft lignin. The synthesis of adhesives is described, and developed adhesives are characterised. Namely, viscosity, mechanical properties of resins and results of differential scanning calorimetry are presented. Furthermore, the developed kraft-lignin-based adhesives were used for the production of particleboards. Pre-pressing in a cold press followed by hot pressing in a laboratory press was used for the production of particleboards. The physical (thickness swelling, moisture uptake, vertical density profile), as well as mechanical (internal bonding, modulus of rupture, modulus of elasticity in three-point bending) properties of particleboards, were evaluated. The results clearly show that kraft lignin can be used for the production of lignin-based adhesives for the production of particleboards.

Activated Carbon from Coconut Shells as a Modifier of Urea–Formaldehyde Resin in Particleboard Production

Various methods for the effective modification of urea–formaldehyde (UF) adhesives, aimed at enhancing the performance of wood-based materials, have been continually explored worldwide. The aim of this work was to investigate and evaluate the effect of introducing small amounts (0.25–1.5%) of activated carbon from coconut shells (ACCS) in UF adhesive on the properties of particleboard. The performed investigations of the adhesive mixture’s properties showed an increase in both viscosity and reactivity. Moreover, the use of loadings of 0.75% and 1% had a positive effect on mechanical properties such as bending strength, modulus of elasticity, and internal bond. In these variants, a delay in the degradation of the adhesive bonds by water was also observed, as indicated by the lower thickness swelling values measured after 2 h. However, under long-term exposure to water, the modification had no considerable effect on the dimensional stability of the boards. Markedly, the addition of 1 and 1.5% of ACCS resulted in a reduction in formaldehyde content, which can be attributed to the excellent adsorption capacity of activated carbon. Overall, a loading of 1% was found to be optimal, resulting in improved strength, enhanced water resistance, and reduced formaldehyde content.

Perspectives on Using Alder, Larch, and Birch Wood Species to Maintain the Increasing Particleboard Production Flow.

Particleboard, engineered wood products as part of a large family of wood composite materials, developed in use mainly in the 1950s and 1960s to utilize inferior wood and wood waste when good-quality wood was in short supply; the annual production capacity worldwide is over 100 million m3. It is also necessary to have a lot of wood raw material for its production, although raw material resources are limited on our planet. In addition to the main wood species, it is therefore possible to think about the wider use of alternative, lesser-known European species of alder, larch, and birch in particleboard production. These three wood species represent an eco-friendly and sustainable wood alternative to the conventional wood raw materials used. This review confirms the diversity of the use of these three species in different fields and proves their suitability in relation to particleboard production. Fundamental research is ongoing in certain universities to determine the proportional shares of use of these tree species in particleboard (in a certain weight proportion in their core layers) for the purpose of formulating the correct technology shares and rules for their application in the wood-based panel industry.

Evaluation of the mechanical and physical properties of particleboards manufactured from rice husk

The effect of rice husk ratios on some physical and mechanical properties of particleboard was investigated. To meet this objective, particleboards with different proportions of wood, rice husk, urea-formaldehyde glue, and other chemicals were produced. The density, moisture content, water absorption, thickness swelling, modulus of rupture (MOR), modulus of elasticity (MOE), internal bond strength, and screw withdrawal resistance of the particleboards were determined. Experimental results indicated that using rice husk in particleboard production improved the dimensional properties of the particleboards. Also, it was found that mechanical properties decreased as the amount of rice husk increased in particleboard production. This is thought to be due to the fact that silica, which is one of the main components of rice husk, weakens the bonding between lignocellulosic raw materials and glue used in particleboard production.

Residential exposure to air pollution and incidence of leukaemia in the industrial area of Viadana, Northern Italy

BackgroundExposure to air pollution has been proposed as one of the potential risk factors for leukaemia. Work-related formaldehyde exposure is suspected to cause leukaemia. MethodsWe conducted a nested register-based case-control study on leukaemia incidence in the Viadana district, an industrial area for particleboard production in Northern Italy. We recruited 115 cases and 496 controls, frequency-matched by age, between 1999 and 2014. We assigned estimated exposures to particulate matter (PM10, PM2.5), nitrogen dioxide (NO2), and formaldehyde at residential addresses, averaged over the susceptibility window 3rd to 10th year prior to the index date. We considered potential confounding by sex, age, nationality, socio-economic status, occupational exposures to benzene and formaldehyde, and prior cancer diagnoses. ResultsThere was no association of exposures to PM10, PM2.5, and NO2 with leukaemia incidence. However, an indication of increased risk emerged for formaldehyde, despite wide statistical uncertainty (OR 1.46, 95%CI 0.65–3.25 per IQR-difference of 1.2 μg/m3). Estimated associations for formaldehyde were higher for acute (OR 2.07, 95%CI 0.70–6.12) and myeloid subtypes (OR 1.79, 95%CI 0.64–5.01), and in the 4-km buffer around the industrial facilities (OR 2.78, 95%CI 0.48–16.13), although they remained uncertain. ConclusionsThis was the first study investigating the link between ambient formaldehyde exposure and leukaemia incidence in the general population. The evidence presented suggests an association, although it remains inconclusive, and a potential significance of emissions related to industrial activities in the district. Further research is warranted in larger populations incorporating data on other potential risk factors.

Study on the characteristics of glass fiber‐reinforced polymers from recycled wind turbine blades as reinforcement in particleboard

AbstractGlass fiber‐reinforced polymer (GFRP), extensively employed in diverse industries, generates considerable waste, especially from decommissioned wind turbine blades. Our research group has developed a new method of mechanical recovery for GFRP from wind turbine blades. In this study, waste GFRP was processed into a mixed particle size of 0.9–6 mm using a crusher and a screening machine, and then added as reinforcement materials to particleboards. The effects of different levels of four factors (GFRP addition, hot pressing temperature, hot pressing time, and binder dosage) on the properties of GFRP particleboards were evaluated by orthogonal experiments. The study results showed that the particleboards with 30 wt% GFRP improved modulus of rupture (MOR), modulus of elasticity (MOE), and internal bonding strength (IB) by 74.94%, 42.28%, and 92.05%, respectively, compared to pure poplar particleboards. Moreover, GFRP particleboards demonstrated better water resistance and dimensional stability than commercial particleboards and excelled in thermal stability. Recycling GFRP waste from decommissioned wind turbine blades and incorporating it into particleboard production can reduce environmental pollution, increase the resource recovery utilization rate, and contribute to sustainable manufacturing practices.Highlights Low‐cost and efficient methods of recycling wind turbine blades were proposed. Recycled GFRP from wind turbine blades can be used as reinforcement for particleboard. The prepared particleboards have excellent physical and mechanical properties and are thermally stable. Determination of the optimal glass fiber‐reinforced polymer addition level in particleboard at 30 wt%.

Sustainable utilization of sugarcane bagasse for wood-based panels: A promising approach for waste management in Egypt

One method to sustainable development is to reduce waste generation and recycle it in a way that contributes to the economic, social, and environmental goals of sustainable development. The study focuses on particle board production from Sugar Cane Bagasse (SCB). Various fiber-matrix combinations were used to create composites using SCB and epoxy resin matrix. Mechanical testing and water absorbance tests were employed to assess the effects of the epoxy content (0–25 wt%). The outcomes demonstrated that the optimal tensile strength of bio composites was attained by the 25 wt% of epoxy with SCB (18.49 Mpa). The water resistance duration property was improved in this study to reach 120 hours by mixing SCB with 25% epoxy. The results show that sugarcane bagasse-epoxy composites demonstrated acceptable mechanical and multifunctional properties. This portrays the effectiveness of Sugarcane bagasse and it a potential competitor to wood-based structural panels. The study uses the open LCA program to conduct a cradle-to-gate life cycle assessment of binder-less particleboard from sugarcane waste manufacturing. Additionally, the study provided an overview of the cost estimation involved in utilizing bagasse as a substitute for MDF particle boards. Furthermore, the influence of pressing temperature on the properties of the particle boards is investigated.

Effect of tannin and calcium lignosulfonate-based adhesives on particleboards production

Laboratory tests were carried out to evaluate the feasibility of producing particleboards with sugarcane bagasse and Eucalyptus sp. and adhesives (tannin pure and lignosulfonate (tannin + lignosulfonate in the proportion of 80:20)). The adhesives were characterized (pH, gel time, viscosity, and density), and the physical and mechanicals properties was realized (water absorption and thickness swelling, moisture content, gravimetric density, density profile by X-ray, elasticity and rupture modulus, and internal bond).The particleboards showed some homogeneity in density. As to the thickness swelling, the means varied from 24.15 % to 35.57 %, with higher averages for those particleboards that used lignosulfonate adhesive. The same effect could be seen in the water absorption test, with emphasis on the tannin-lignosulfonate adhesives, with averages 18.5 % higher than those of pure tannin, regardless of the type of material. Based on the internal bond test, the highlight was the treatment with 100 % wood particles and pure tannin adhesive. As sugarcane bagasse was added, there was a reduction in modulus of elasticity, independently of the adhesive used. The results highlighted the using lignosulfonate as a component obtained inferior results when compared to those of pure tannin, mainly concerning humidity and the internal bond test. As well as a gradual loss of strength as the wood was replaced by sugarcane bagasse. In this aspect, environmental issues are gained as waste is used; in such uses, such properties are not required.

Use of scrap particleboard to produce recycled particleboard

Recycling is presently the most environmentally friendly approach that deals with wood waste. Each year a huge amount of particleboard completes its service life and needs to be disposed of or recycled. Scrap particleboard has the potential to be reused as raw material for particleboard production. A crucial step for producing particleboards using scrap particleboards is to break down urea-formaldehyde (UF) resins in the scrap particleboards to obtain separated particles. In this study, liquid hot water (LHW) pretreatment was employed to decompose the UF resins to detach and recover wood particles from the scrap particleboards. The recovered wood particles and fresh industrial wood particles in different proportions were used as the raw material for the particleboard. The physical and mechanical properties of the recycled particleboards were evaluated. The modulus of rupture (MOR), modulus of elasticity (MOE), and internal bond (IB) of the recycled particleboards were lower than those of the particleboards made with fresh wood particles. However, the 2 h thickness swelling (TS) of the recycled particleboards was better than that of the fresh particleboards, indicating that the recycled particleboards were more dimensionally stable. The mechanical properties of the particleboards containing up to 40% recycled wood particles met the minimum Chinese National Standard requirements for general-purpose particleboards. Conclusively, scrap wood particleboards could be utilized as raw material in particleboard production.