feasibility of manufacturing paper-plastic laminates using waste paper taiwan forestry research...

Feasibility of Manufacturing Paper-

Plastic Laminates Using

Waste Paper

Taiwan Forestry Research Institute

Chin-Yin Hwang

2007 IUFRO ALL DIVISION 5 CONFERENCE

11-02-2007 Taipei, Taiwan

Some Statistics. . . . .

0

20

40

60

80

1997 1998 1999 2000 2001 2002 2003 2004 2005 2006

(%)

1

Waste Paper Recovery Rate in Taiwan

(Taiwan Paper Industry Association, 2007)

69.7

Paper Recycling Procedures. . . .

1

Collection

Classification

Disintegration

Washing

Deinking

Cleansing

Bleaching

Forming

Drying

2

Some Questions. . . . .

3


Is there other options for Paper Recycling?

3



Can other materials be reclaimed from the waste stream and combined with waste papers?

3



Can other materials be reclaimed from the waste stream and combined with waste papers?

Is woodfiber plastic composites a possibility?

3

Some Problems with Woodfiber Plastic Composites

Reduction in Composite S

trength

Inherent H Bond

Agglomeration of wood fibers

Heterogeneous fiber dispersion

Inferior interfacial adhesion

Vigorous mixing

Reduced fiber aspect ratio

Reduced fiber strength

4

Why Paper-Plastic Laminates?

• Avoid elaborated paper recycling procedures….

• Reduce agglomeration b/w fiber and plastic

• Preserve aspect ratio of fiber

• Preserve H-bond of paper

5

How PPL is Made?

＋ Interleaving

Hot Press

＋Impregnation

orCoating

SheetFormation

＋

6

Material

• Paper: office paper

• Plastic: PE films, 0.03mm, 0.06mm, 0.09mm

NP, Not-Printed P, Printed

V, Virgin R, Recycled

7

Factors of Interest. . . . .

• Paper type (P, NP)

• Plastic type (V, R)

• Plastic film thickness (0.03, 0.06, 0.09 mm)

8

Methods: preparation

＋

OVEN

NP-R-3

NP-R-6

NP-R-9

NP-V-3

NP-V-6

NP-V-9

P-R-3

P-R-6

P-R-9

P-V-3

P-V-6

P-V-9

HP

IL

9

Typical Hot Press Scheme

10

cool off

0

50

100

150

200

0 5 10 15 20 25 30 35 40 45 50

Time (min)

Tem

pera

ture

(C)

set temperature

response temp.

Methods:

• Flexural Properties (MORb, MOEb)• Tensile Properties (MORt, MOEt)• Notched Izod Impact Bending• Hardness (Shore D)• Heat Deflection Temperature

Mechanical Properties

11

Sample Preparation SchemeFlexural

Izod

Hardness

Tensile

HDT12

Resulting PPLs

13

• Treatment combination: 12• Replicate: 5• Sp/Gr: 0.93 to 1.05 gm cm-3

• Compaction ratio: 1.17 to 1.23 • Fiber loading: 48, 60, and 72%

0

20

40

60

80

100

0.03 0.06 0.09

Plastic Film Thickness (mm)

MO

Rb

(M

Pa

)

NP-R NP-V P-R P-V

Flexural Properties - MORb

44.8 ~ 69.8 MPa, overall avg 56.1 MPa

14

0

20

40

60

80

100

0.03 0.06 0.09


MO

Rb

(M

Pa

)

NP-R NP-V P-R P-V



14

Different trends with different plastic groups

NP-R, P-R decreased with increasing plastic film thickness

NP-V, P-V showed highest MORb at 0.06mm

0

20

40

60

80

100

0.03 0.06 0.09


MO

Rb

(M

Pa

)

NP-R NP-V P-R P-V


44.8 ~ 69.8 MPa

14


PPL 39.1~56.2 MPa (Michell et al. (1978) )

0

20

40

60

80

100

0.03 0.06 0.09


MO

Rb

(M

Pa

)

NP-R NP-V P-R P-V


44.8 ~ 69.8 MPa

14


5.9~39.6 MPa

(Woodfiber-PE composites)

0

20

40

60

80

100

0.03 0.06 0.09


MO

Rb

(M

Pa

)

NP-R NP-V P-R P-V


44.8 ~ 69.8 MPa

14


5.9~39.6 MPa


1.41 times

0

2

4

6

8

10

0.03 0.06 0.09


MO

Eb

(G

Pa)

NP-R NP-V P-R P-V

Flexural Properties - MOEb

4.2 ~ 7.3 GPa, overall avg 5.39 GPa

15

0

2

4

6

8

10

0.03 0.06 0.09


MO

Eb

(G

Pa)

NP-R NP-V P-R P-V



15

Similar trends with the corresponding MORb results, except

that P-V remained unaffected at all PLFT levels.

i.e., NP-R, P-R decreased with increasing plastic film thickness

NP-V showed highest MOEb at 0.06mm

0

2

4

6

8

10

0.03 0.06 0.09


MO

Eb

(G

Pa)

NP-R NP-V P-R P-V



15

PPL 5.8~7.6 GPa (Michell et al. (1978) )

0

2

4

6

8

10

0.03 0.06 0.09


MO

Eb

(G

Pa)

NP-R NP-V P-R P-V



15

0.8~3.6 GPa


0

2

4

6

8

10

0.03 0.06 0.09


MO

Eb

(G

Pa)

NP-R NP-V P-R P-V



15

0.8~3.6 GPa


1.49 times

0

20

40

60

80

100

0.03 0.06 0.09


MO

Rt

(MP

a)

NP-R NP-V P-R P-V

Tensile Properties - MORt

16

30.4 and 56.9 MPa, overall avg 39.9 MPa

0

20

40

60

80

100

0.03 0.06 0.09


MO

Rt

(MP

a)

NP-R NP-V P-R P-V


16


Different trends with different paper types

NP-V, NP-R decreased with increasing plastic film thickness

P-V, P-R showed highest MORt at 0.06 mm

0

20

40

60

80

100

0.03 0.06 0.09


MO

Rt

(MP

a)

NP-R NP-V P-R P-V


16


10.0~27.0 MPa


0

20

40

60

80

100

0.03 0.06 0.09


MO

Rt

(MP

a)

NP-R NP-V P-R P-V


16


10.0~27.0 MPa


1.48 times

0

20

40

60

80

100

0.03 0.06 0.09


MO

Et

(GP

a)

NP-R NP-V P-R P-V

Tensile Properties - MOEt

17

45.6 ~86.2 GPa, overall avg 62.4GPa

0

20

40

60

80

100

0.03 0.06 0.09


MO

Et

(GP

a)

NP-R NP-V P-R P-V


17


No specific trend was found

0

20

40

60

80

100

0.03 0.06 0.09


MO

Et

(GP

a)

NP-R NP-V P-R P-V


17


1.0~2.7 GPa


0

20

40

60

80

100

0.03 0.06 0.09


MO

Et

(GP

a)

NP-R NP-V P-R P-V


17


1.0~2.7 GPa


23 times???

Notched Izod Impact Properties

18

0

100

200

300

400

500

0.03 0.06 0.09


Izo

d Im

pac

t (J

/m)

NP-R NP-V P-R P-V

139.2~371.0 J/ m


18

0

100

200

300

400

500

0.03 0.06 0.09


Izo

d Im

pac

t (J

/m)

NP-R NP-V P-R P-V

139.2~371.0 J/ m


NP-V, NP-R showed highest Izod at 0.06 mm

P-V, P-R showed no specific trend


18

0

100

200

300

400

500

0.03 0.06 0.09


Izo

d Im

pac

t (J

/m)

NP-R NP-V P-R P-V

139.2~371.0 J/ m

14~27 J/m (Woodfiber-PE composites)


18

0

100

200

300

400

500

0.03 0.06 0.09


Izo

d Im

pac

t (J

/m)

NP-R NP-V P-R P-V

139.2~371.0 J/ m

14~27 J/m (Woodfiber-PE composites)

>5 times

Hardness

19

0

20

40

60

80

100

0.03 0.06 0.09


Ha

rdn

ess

(Sh

ore

D)

NP-R NP-V P-R P-V

64.2 ~72.6

50 Shore D

Commercial LDPE

Hardness

19

0

20

40

60

80

100

0.03 0.06 0.09


Ha

rdn

ess

(Sh

ore

D)

NP-R NP-V P-R P-V

64.2 ~72.6

50 Shore D

Commercial LDPE


NP-V, NP-R showed lowest hardness at 0.09 mm

P-V, P-R seemed to converge at 0.06 mm

Heat Deflection Temperature

20

100

110

120

130

140

150

0.03 0.06 0.09


He

at D

efl

ecti

on

Tem

per

atu

re (

oC

)

NP-R NP-V P-R P-V

HTD of LDPE: 47.0~50.0℃

121.6 ~130.0

Limitations

21

• Size and shape (length, width, thickness)• Processability (higher stiffness, HDT)• Anisotropy • Durability unknown• Applications

Conclusion

22

MORb, MOEb, MORt,and Izod of PPLs were better than re

ported WPCs.

The PPLs prepared in this study exhibited 1.5-times the fle

xural strength and stiffness and 5-times the notched Izod i

mpact strength over extruded woodflour-plastic composites.

Except for tensile stiffness, all the other mechanical propert

ies of the PPLs were affected by interactions among the 3 f

actors.

Conclusion

22

PPLs with the same plastic type tended to show s

imilar trends in flexural properties, whereas PPLs

with the same paper type tended to exhibit similar

trends in tensile strength at break, Izod impact str

ength, and hardness.

Conclusion

22

These results indicate that PPLs may be a viable

alternative method of paper recycling. However, f

urther studies to address the long-term performan

ce of PPLs under extreme conditions are recomm

ended.

Feasibility of developing PPL as a paper recycling

alternative seems to be encouraging.

tHE eND

Questions?

feasibility of manufacturing paper-plastic laminates using waste paper taiwan forestry research...

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