formable cellulosic material for packaging
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Formable cellulosic
material for packaging Overview of the FuBio JR2 WP4 Task 2
FIBIC Seminar 27.8.2013
29.8.2013 FuBio Seminar
Elias Retulainen VTT Technical Research Centre of Finland
FuBio JR2 29.8.2013 Presenter
Research partners
• Aalto University – Janne Laine & Alexey Khakalo
• Åbo Akademi – Pedro Fardim & Jasmina Obradovic
• LUT – Henry Lindell & Panu Tanninen
• VTT – Elias Retulainen , Alexey Vishtal, Erkki Salo, Pirjo Heikkilä
Fibre based products of future
replacement of oil-based
materials with fibre based
materials
new shapes for paperboard
packaging
new functional properties for
paper based packaging;
modified atmospheric
packaging
new types of packaging lines
Deep drawn shapes, TU Dresden (Hauptmann& Majschak
(2011))
Thermoformed tray, VTT
Objective: To produce fibre-based, web-like material suitable for production of advanced 3D-shapes for packaging i.e. “Moldable Web”
FuBio JR2 29.8.2013 Presenter
Challenge: Failure elongation of fibres and paper is low
Straight single fibres (Jentzen
1964)
Paper made of beaten softwood
fibres (Seth & Page 1981)
The main challenge is due to the fact that cellulose is inherently very stiff, partially crystalline material.
FuBio JR2 29.8.2013 Presenter
Research approaches Fibre
material
Complete or
partial dissolution
of cellulose
Mechanical
modification of
fibres
Modification of
fibre joints
Modification of
fibre network
Electrospinning
DMALiCl and
NaOH-urea
swelling
EmimOAc-
solvent swelling
& dissolution
High-
consistency
treatment
Combined high-
and low-
consistency
treatment
Spray addition
of proteins
Spray and
coating addition
of film-forming
carbohydrates
Compaction of
wet paper
Unrestrained
drying
&
FuBio JR2 29.8.2013 Presenter
Formability testing
Adjustable
packaging line
2D-formability
tester 3D-forming
device Deep-drawing
Air
forming/Vacuum
forming
Formability testing platform
Aims to understand requirements for good formability in different industrial forming processes
Mouldable cellulose
Jasmina Obradovic & Pedro Fardim
Laboratory of Fiber and Cellulose Technology
Åbo Akademi, Turku, Finland
FuBio JR2 WP4 Task 2
Concept of 3D objects prepared by cellulose swelling in DMAc/LiCl solvent system
Use of acrylate epoxidized soybean oil (AESO) as a plasticizer
Another approach using NaOH/urea as a swelling agent for cellulose
X-ray results
Reference pulp
Swelled pulp in DMAc/LiCl
Swelled pulp in DMAc/LiCl and removed solvent
0
100
200
300
400
500
600
700
0 10 20 30 40
Counts
Position 2Ө
Raman results
Reference pulp
Swelled pulp in DMAc/LiCl
Swelled pulp in DMAc/LiCl and removed solvent
Preparation of 3D cellulose objects
previously swelled in DMAc/LiCl solvent
system
RESULTS: AALTO UNIVERSITY Alexey Khakalo & Janne Laine
29.8.2013 FuBio Seminar
40
45
50
55
60
65
70
75
80
85
8
10
12
14
16
18
20
Te
ns
ile
In
de
x, N
m/g
Elo
ng
ati
on
at
bre
ak
, %
Stretch, % Tensile Index, Nm/g
Mechanical properties of cellulose-
gelatin composites
Extensibility increases with the amount of gelatin added, TI is max at 8% addition
10
Grammage 175 g/m2,
Spraying of gelatin solution on prepared paper sheet
before wet pressing, free drying
Calculated masses
for adsorbed gelatin
11
pH 4 pH 10
COOH COO-
NH3+ NH2
pH 4 pH 5.8 pH 10
QCM-D (Wet weight) Thickness
(nm) 7.75 ± 0.05 21.64 ± 0.14 12.77 ± 0.1
Δm (mg/m2) 9.3 ± 0.2 26 ± 0.2 15.3 ± 0.2
SPR (dry weight) Thickness
(nm) 0.3 ± 0.05 1.9 ± 0.1 0.5 ± 0.05
Δm (mg/m2) 0.4 ± 0.05 2.5 ± 0.1 0.65 ± 0.05
Water (%) 95.7 90.4 95.7 0
1
2
3
4
5
6
7
Gelatin pH 4 pH 5.8 pH 10
O/N
ra
tio
Quantifying gelatin
adsorption using XPS
• The adsorption of gelatin to cellulose was found to be highest at isoelectric pH 5.8
• Hydrogen bonding is likely the dominant interaction between cellulose and gelatin
• The adsorbed layer contains a significant amount of coupled water
Topographical changes of gelatin modified
cellulose surfaces
Rq 0.473 nm
Gelatin, pH 4 Gelatin, pH 5,8 Gelatin, pH 10
-1,5
-1
-0,5
0
0,5
1
1,5
2
0 0,5 1
nm
µm
-1,5
-1
-0,5
0
0,5
1
1,5
0 0,5 1
µm
-2
-1,5
-1
-0,5
0
0,5
1
1,5
0 0,5 1
µm
-2
-1,5
-1
-0,5
0
0,5
1
1,5
0 0,5 1
µm
200 nm 200 nm 200 nm 200 nm
Cellulose
Rq 0.764 nm Rq 0.599 nm Rq 0.817 nm
1x1 µm2 AFM height images and corresponding roughness
profiles, tapping-mode 12
RESULTS:VTT Alexey Vishtal & Elias Retulainen
29.8.2013 FuBio Seminar
Combined approach for improved formability
SW Kraft
pulp
High-
consistency
treatment
Low-
consistency
refining
Spraying
with
polymers
Compaction of
fibre web Unrestrained
drying
Ensuring
softening of
polymers in
forming
1. 2.
30% DS,
Wing
defibrator
3.
21-25
SR
,
Valley
beater
4.
1-4%,
carbohydrate,
+optionally
croslinker or
softener
5.
Laboratory
compaction
device, 55-
65% DS
6.
Between two wires,
gap 1-3 mm, Drying
shrinkage up to 15%
7.
Adjusting temperature and
moisture content of paper
in forming.
Extensibility 4%
Extensibility 7-8%
Extensibility 9-11%
Extensibility 12-
15%
Extensibility up to 30%
Improvements in
formability 2-4%-points
Most of these
methods can be
implemented in
industry without
major capital costs
Handsheets
FuBio JR2 29.8.2013 Presenter
Demo shapes & current progress
• The combined approach is a flexible tool to adjust paper to a certain forming process
• Besides formability, other properties can be also improved
• Four sets of the demo-materials were produced at the moment (trays, cups, lids etc.)
• The lab made VTT material have shown superior convertibility to the commercial samples
Sliding Fixed blank
RESULTS: LUT Henry Lindell & Panu Tanninen
29.8.2013 FuBio Seminar
LUT - Adjustable Packaging Line
− A testing platform for evaluating convertability of
barrier coated products with particular
emphasize on die cutting, folding and creasing.
Manufacturing of converting tools was finalized
Q1/2012.
− Test tray used in converting trials was designed
to be relatively demanding to form in order to
obtain differing results between studied materials.
− Test run of FuBio-materials consist of two stages:
− Die cutting of coated paperboard sheets into
tray blanks.
− Press forming of the blanks into trays
− Study of critical steps in converting of biobarrier
materials - insight into creasing and cutting tools
in converting (Q2/2013 )
− Materials are produced by subtask 1.6
(LUT/Backfolk).
FuBio JR2 29.8.2013 Presenter
Summary
• Several approaches have been taken to make formable material from wood fibres and test its formability. The main challenge is due to the fact that cellulose is inherently stiff, partially crystalline material with low elongation potential.
• Possibility of utilization of DMa/LiCl and NaOH/Urea solvent systems for modification of cellulose, and production of 3D-shapes was investigated
• Addition of gelatin can improve elongation of freely-dried paper from 10 to 18% and strength from 55 to 75 Nm/g
• Gelatin was adsorbed by cellulosic fibres irreversibly
• Extensibility as high as 30% was obtained by combining several methods • Requirements for good formability in different forming processes were studied and
evaluated
• Influence of the die-cutting , creasing and pressure forming on the performance of bio-based coatings was evaluated with trays
FuBio JR2 29.8.2013 Presenter
Acknowledgements
The support and assistance of colleagues from the Fubio JR 2 WP4 Task 2 in preparation of this presentation is acknowledged
The support of VTT Graduate school and The International Doctoral Programme in Bioproducts Technology PAPSAT to Alexey Vishtal is acknowledged
Thank You!
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