very thin medium density fibreboards (mdf) with paperboard … · 2014-08-23 · very thin medium...
TRANSCRIPT
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 1 Christoph Wenderdel
Very Thin Medium Density Fibreboards (MDF) with Paperboard-like Properties as Reusable
Packaging Material
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 2 Christoph Wenderdel
Market data for cardboards for packaging (Germany)▫ growth for period 2008 – 2012 of 12 %,
▫ production in 2012 of 10.5 mill. t of paper, card- and paperboards for packaging purposes,
▫ assortments and shares:
‐ brown paper and paper for corrugated boards (69 %),
‐ cardboard (27 %),
‐ mill board (1 %),
‐ wrapping paper (3 %).
Market of packaging material shows great potential!
Also for wood based panel industry?
Current situation
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 3 Christoph Wenderdel
Calculation of production factors for 1 mm MDF in comparison to 1 mm cardboard.
▫ Thin MDF as substitute for cardboards as packaging material offers following advantages:
‐ savings in process water (¾ and more),
‐ lower energy consumption,
‐ omitting process chemicals,
‐ lower amortisation costs.
production costs are possibly lower,
very good carbon and water footprints.
Current situation
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 4 Christoph Wenderdel
Thin MDF are not suitable for the same applications as conventional cardboards for packaging purposes.
Problem:▫ Product properties,
‐ inadequate foldability,
‐ lack of recyclability.
▫ Production technology,
‐ laying of fibre mat,
‐ accuracy and speed of hot-press.
Problem
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 5 Christoph Wenderdel
Development of “dry cardboard” ▫ possible to manufacture with state of the art MDF-technology,
▫ with grammages of 300 – 800 g/m²,
▫ applicable as packaging material,
▫ guaranteed recyclability in waste-paper stream,
▫ acceptable foldability,
▫ comparable strength and stiffness in comparison to wet-process cardboard,
▫ ecological and economical advantages.
Objective
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 6 Christoph Wenderdel
Approach
Technological adaption ▫ pneumatic-mechanical mat laying,
▫ adapted press parameters (temperature, time, pressure).
Raw material▫ fibre pulp
‐ MDF fibres with modified pulping conditions,
‐ addition of differently conditioned recovered paper,
▫ additives
‐ omitting conventional thermosetting condensation resins,
‐ use of natural binders such as starch, proteins.
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 7 Christoph Wenderdel
Materials
Fibre pulp▫ Raw material: Scots pine and recovered paper,
▫ Digester cond.: 160 °C for 3-4 min.,
▫ Defibrator: 12 inch laboratory refiner,
▫ Grinding gap: 60 µm,
▫ Driving speed: 3,000 rpm,
▫ Flash dryer temp.: 90 °C.
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 8 Christoph Wenderdel
Materials
Application of additives▫ additives: starch, protein, wheat flour, PVAc,
▫ application: blowline,
▫ content: 10 % to absolutely dry mass of fibres.
Additive Recovered paper content / %0 10 20 30 50
Starch St_0 St_10Protein Pr_0 Pr_10 Pr_20 Pr_30 Pr_50Wheat flour Wf_0 Wf_10PVAc PV_0 PV_10
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 9 Christoph Wenderdel
Technology
Mat laying with Airlaid technology
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 10 Christoph Wenderdel
Technology
Mat laying with Airlaid technology
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 11 Christoph Wenderdel
Technology
Production parameters▫ grammages: 250 – 600 g/m²,
▫ target density: 700 kg/m³,
▫ cardboard layer: single- and multilayer,
▫ MC fibre mat: rewetted to 13 %,
▫ spec. pressure: 5 – 10 bar,
▫ press temp.: 170 – 210 °C,
▫ press time factor: 10 – 15 sec/mm.
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 12 Christoph Wenderdel
Characterisation
Cardboard properties▫ thickness DIN EN 20534
▫ mass per unit area DIN EN ISO 536
▫ burst index DIN 53141-1
▫ bending stiffness DIN 53121
▫ folding behavior DIN 55437-2 and DIN 55437-3
▫ recyclability PTS-RH 021/97 and INGEDE-Methode 13
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 13 Christoph Wenderdel
Characterisation
Folding behaviour▫ according to standard only differentiated between pass / fail test,
Method to assess folding behaviour was established.
10 very good (passed test)
…
…
…
…
1 very poor.
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 14 Christoph Wenderdel
Results
Burst index with respect to additive
wet-process
cardboard
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 15 Christoph Wenderdel
Results
Burst index with respect to recovered paper content / layering
wet-process
cardboard
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 16 Christoph Wenderdel
Results
Bending stiffness with respect to recovered paper / layering
wet-process
cardboard
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 17 Christoph Wenderdel
Results
Foldability with respect to recovered paper / layering
wet-process
cardboard
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 18 Christoph Wenderdel
Conclusion
Dry cardboards are feasible to manufacture with▫ optimized raw material combination,
▫ adaptation of mat laying and optimising pressing process,
▫ excellent mechanical properties,
▫ fully given recyclability,
▫ acceptable foldability until now only in multilayer.
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 19 Christoph Wenderdel
Acknowledgement
The presented work was supported by the German Federal Ministry of Economics and Technology at the decision of the German Bundestag (IGF: 16911 BG).
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 20 Christoph Wenderdel
Contact persons
Institut für Holztechnologie Dresden gemeinnützige GmbH▪ Tino Schulz
[email protected]+49 351 4662 263
▪ Christoph [email protected]+49 351 4662 256
▪ Detlef [email protected]+49 351 4662 342
Papiertechnische Stiftung Heidenau ▪ Alf-Mathias Strunz
[email protected]+49 3529 551 684
57th International Convention of Society of Wood Science and Technology, Zvolen, June 23-27, 2014Folie 21 Christoph Wenderdel
Thank you!