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SUSTAINABLE PAPER
      PACKAGING
(PEMBUNGKUSAN KERTAS
        LESTARI)
  INTERNATIONAL SYMPOSIUM ON
   CURRENT ADVANCEMENT AND
RESEARCH IN TEXTILE & PACKAGING
         TECHNOLOGY

     Wan Rosli Wan Daud
   Universiti Sains Malaysia
Packaging falls into a number of
  categories:
§ Primary –packaging in contact with the
  product.
§ Secondary –‘outers’ which hold a number of
  packed products as a unit of say 10 or 12.
§ Tertiary –stretch wrapped pallets which hold
  perhaps 100 ‘outers’ or cases.
PACKAGING
Purposes:
§ Contain
§ Inform
§ Protect
§ Transport
§ Display
PACKAGING
put in another way:
§ is a means of ensuring safe delivery of a
  product to the ultimate user in a sound
  condition at a minimum overall cost
  § Science
  § Art
  § Technology
ELEMENTS OF PACKAGING:

§ Materials
§ Design
  - address the issue of wastage
     - under-packaging cause damage and
       spoilage to contents
     - over-packaging wasting resources
     - goal is “RIGHT SIZE” packaging
  - packaging design software eg PIQET,
    Australia (Packaging Impact Quick Evaluation
    Tool); TOPS, USA (Total Optimization
        );
    Packaging Software)
Materials
§   Metals (aluminum & steel)
§   Glass
§   Polymers (Plastics)
§   Wood/Composites
§   Paper
SUSTAINABILITY
§ Measures taken by various sectors to
  allay fears of sustainability centers
  around the traditional waste management
  hierarchy – 3R’s
  § Reduction
  § Reuse
  § Recycling/Recovery
Sustainable Paper Packaging
Sustainable Development
Entered the public debate after the World
Commission on Env. And Dev. Published
their landmark report “OUR COMMON
FUTURE “ in 1987
Reiterates the most often quoted
definition (Brundtland Commission
(United nations, 1983):
  “meets the needs of the present
  without compromising the ability of
  future generations to meet their own
  needs”
  needs”
Sustainable packaging
§ Is beneficial, safe & healthy for individuals and
  communities throughout its life cycle;
§ Meets market criteria for performance and cost;
§ Is sourced, manufactured, transported, and recycled
  using renewable energy;
§ Optimizes the use of renewable or recycled source
  materials;
§ Is manufactured using clean production technologies
  and best practices;
§ Is made from materials healthy in all probable end-of-
  life scenarios;
§ Is physically designed to optimize materials and
  energy;
§ Is effectively recovered and utilized in biological
  and/or industrial closed loop cycles.
                            www.sustainablepackaging.org
Sustainable Development
Most often quoted definition (Brundtland
Commission (United nations, 1983):
  “meets the needs of the present without
  compromising the ability of future generations to
  meet their own needs”
                 needs”
Can be conceptually broken into three
constituent parts:
 § environment,
 § economic and
 § social
Sustainable Development




Model of sustainable development: at the
confluence of three constituent parts
§ With paper packaging there has never
  been an issue regarding sustainability
  – its always sustainable
§ WHY?
Sustainable Paper Packaging
Environmental Dependable

 § Made from renewable resources
 § One of the highest recovery rate of all
   packaging
      - almost 60% of paper are recycled
 § Almost total compostable
Socially Dependable
§ Produced by manufacturers who
  practised high safety standards
     – ISO 9000 series
§ Charitable donations from companies to
  community
§ Industry involve educating the public the
  importance of recycling through school
  and outreach programs
Economically Dependable
§ Contributing to the nations’ economy
§ Creation of jobs
So what’s the
problem?
§Paper packaging consumption
steadily rising over the years
CONSUMPTION OF CORRUGATING
                      MEDIUM IN MALAYSIA
X000 TONNES



              600
              400
              200
                0
                    1992     1996        2000        2004       2008

                                         YEAR

                           Asian paper Packaging Historical Data, 2009
§Problems in sourcing of and
quality of raw material
§Issue of Raw Material
Sustainability
Social                  Environmental
 sustainability             sustainability




                SUSTAINABLE
              PAPER PACKAGING



 Raw material                 Economic
 sustainability             sustainability



 FACTORS IMPACTING SUSTAINABLE PAPER
PACKAGING, AND THEIR INTERDEPENDENCE
RAW MATERIAL
SUSTAINABILITY
Raw material for paper and paper
packaging are the cellulose fibers
§ hygroscopic property (absorb moisture)
Malaysia being in the equatorial region
has high humidity
§ effect on paper strength properties
How to overcome this problem?

           Yield Pt.               NSSC

                                   KLB

                                   UKP
  Load

              1




                       Stretch

         High Humidity Resistance of
               Various Pulps
Another critical issue
  relating to raw material
  sustainability is Quality of
  raw material
§ Basically most of all paper packaging in
  Malaysia uses recycled fibers
§ Problem of strength
Sustainable Paper Packaging
Sustainable Paper Packaging
Sustainable Paper Packaging
Strength of paper
diminishes upon
recycling
KRAFT PULP




             32
due to
HORNIFICATION
§ Loss of swelling ability of
  cellulosic fiber upon drying
 § due to the closure of pore
   spaces in the cell walls, plus
 § the inability of many of the
   pores to reopen if the fibers are
   rewetted
WETTING
       A                                       B
                      DRYING



Progressive swelling of fibre wall: from A to D
Progressive shrinkage of fibre wall: from D to A




                                                   C
                  D


                                                       35
DRIED FIBRES
                NEVER-DRIED FIBRES




               CHEMICAL PULP FIBRES

                                      36
Factors that influence
   Hornification

§ High-yield pulps, such as
  thermomechanical pulp (TMP),
  appear to be much less
  susceptible to changes when they
  are dried
MECHANICAL
            PULPS




CHEMICAL
  PULPS


                   38
RESTORATIVE
TREATMENTS
a) Refining
b) Fractionation
c) Chemical additives
  § Starches
  § Polyacrylamides (PAM)
d) Blending with virgin fibers
Where do we get the virgin
fibers from?
MALAYSIA - SOURCES OF IMPORTED
                VIRGIN PULP
                          Others,
                           11% Chile,
                                 4%
                                  Canada,
                                    5%
                                      Thailand, 7%


     USA, 59%
                                New Zealand,
                                    14%

Importation of wood pulp to Malaysia is
dominated by USA
Total imports of wood pulp in 2002 is ca.
RM138 Million with a growth of 5.6%
compared to 2001
“Let the building and
  other critically wood-
                   wood-
dependent industries use
  wood. Pulp and paper
 industry should opt to
non-
non-wood and wastes for
     sustainability”
     sustainability”

            Ako Norlander, Appita J. 2008
Pulp from oil palm
biomass as
reinforcement in
recycled fibers
Palm oil constitutes only 10% of the palm
production while the rest is biomass
The biomass (waste residues) generated
from this industry throughout harvesting and
processing activities as well as during
replanting is enormous
 § Estimated to be 60-100 million tonnes (wet)
                   60-
Forms of waste residues:
 § Empty fruit bunches (EFB)
 § Fronds
 § Trunks
BIOMASS/PRODUCTS FROM
     OIL PALM TREE


                      Fronds



                                    Empty Fruit
                                      Bunch


                Fresh Fruit Bunch




                                    Crude Palm
                                        Oil

Oil Palm Tree
                      Trunk
§ An estimation, based on a planted area of
  25,700 million m2, and a production rate of dry
  oil palm biomass of 20,336 kg per 10,000 m2
  per year, shows that Malaysian palm oil
  industry produced approximately 56.9 million
  tonnes of lignocellulosic biomass in 2000.
§ Taking into account the proportion of useful
  fibrous elements that can be extracted from
  various oil palm components, an overall
  recovery rate of 75% and a pulp yield of 45%,
  the net useful bleached pulp would amount to
  about 14.8 million tonnes
§ VERY SUSTAINABLE
OCC FIBER




           +
EFB PULP




   =
           PAPER ROLL
EFFECT ON BURST STRENGTH

              160
              140
Burst Strength kPa


              120
              100
                     80
                     60
                     40
                     20
                      0
                          0%   20%   40%     60%     80%   100%

                                     Pulp addition
EFFECT ON RING CRUSH

             60
RING CRUSH (N)


             40




             20



                 0

                 0%   20%   40%       60%     80%   100%
                            % Pulp addition
Sustainable Development
For a sustainable pulp production
§ other than a continuous supply and availability
  of raw materials,
§ the processes involved in the production of
  pulp and paper have to be environmentally
  friendly
§ Nevertheless, process(es) must be economic
  viable, if not it will just be an academic study,
  without having much impact on the society in
  the long term
Kraft, Sulfite

                 Pulping


 Raw material                    Unbleached Pulp




                             Cl2 & derivatives

Bleached Pulp
                   PRODUCTION OF PULP
These processes (esp. bleaching) are
known to generate serious environmental
drawbacks
§ Chlorine reacts with lignin, to form chlorinated
  organic compounds (e.g., dioxin)
                             dioxin)
   o believed to be carcinogenic to humans based on
     results of laboratory studies with animals




§ The presence of these chlorinated compounds
  has also been linked to adverse ecological
  effects on wildlife in receiving waters
§ And to reduce these shortcomings,
  it is imperative that alternative
  methods which are cleaner and
  environmentally friendly are used
§ ENVIRONMENTALLY
  SUSTAINABLE
ENVIRONMENTAL
       SUSTAINABILITY
§ Environmental sustainability is
  defined as the ability of the
  environment to continue to function
  properly indefinitely
§ Goal to minimize environmental
  degradation, and to halt and reverse
  the processes they lead to
§ Clean Technologies for Pulp
  Production
CLEAN TECHNOLOGIES
      CONCEPT
“manufacturing processes or product
technologies that reduce pollution or
waste, energy use, or material use in
comparison to the technologies that
they replace”
  process(es) must be economic viable, if
  not it will just be an academic study,
  without having much impact on the society
  in the long term
  environmentally friendly –
   SULFUR FREE PULPING AND CHLORINE
   FREE BLEACHING
CLEAN TECHNOLOGY FOR
               PULP PRODUCTION

  Oil Palm                   Pretreatment
                       1. Soaking
 Empty Fruit           2. Washing
                                   Oily substance removal

   Bunch               3. Mechanical process – silica
                          removal
  (In strand form)


  Unbleached              Pulping
EcoPalm Pulp™          Extended Soda
                       Anthraquinone

TCF Bleaching
1. Oxygen                     Bleached
2. Ozone                   EcoPalm Pulp™
3. Hydrogen Peroxide
COMPARISON OF PAPER PROPERTIES
     FROM OIL PALM EFB AND
  COMMERCIAL HARDWOOD PULPS
         (UNBLEACHED)
            Tensile   Tear Index Burst
            Index     (mN.m2g-1) Index
            (Nm/g)               (kPa.m2g-1)
Commercial 13.21      3.14       1.0
Hardwood
Empty Fruit 15.81     3.85       1.20
Bunch
COMPARISON OF PAPER PROPERTIES
       FROM OIL PALM EFB AND
    COMMERCIAL HARDWOOD PULPS
            (BLEACHED)
                         25


                         20


                         15


                         10


                         5


                         0
                              Tensile Index    Tear Index   Burst Index   Brightness
                                 (Nm/g)       (mN.m2g-1)    (kPa.m2g-1)    (x 10%)
Commercial Hardwood Pulp         19.55            2.6           1.4          8.43
Empty Fruit Bunch Pulp           20.41           2.72          2.46          8.33
POTENTIAL PRODUCT APPLICATION(S)

  Unbleached virgin pulp (Unbleached
  EcoPalm Pulp™) which can be used in
             Pulp™)
  full or mixed with wastepaper depending
  on the final product
  Bleached virgin pulp (Bleached
  EcoPalm Pulp™) which can be used in
            Pulp™)
  the production of writing and printing
  paper
Yield Pt.               NSSC

                                 KLB

                                 UKP
Load
            1




                     Stretch

       High Humidity Resistance of
             Various Pulps
MECHANICAL
            PULPS




CHEMICAL
  PULPS


                   63
Alkaline Peroxide
 Mechanical Pulping
       (APMP)
process involves the impregnation
of the chips with an alkaline
peroxide bleach liquor in one or
more steps prior to atmospheric
refining, hence combining pulping
and bleaching in a single operation
Attractive Features of
            APMP
§ High yield (85% on average), compared
  to 50% or lower yield of chemical pulping
§ High brightness – use of peroxide
§ Can also be use for newsprint
DESIGN
SUSTAINABILITY
Packaging Source
  Reduction
§ Avoid unnecessary components
  § Eg: Toothpaste boxes have been
    eliminated in countries with strict waste
    laws
§ Reduce amount of material
  § Eg. Nike
Nike
“Lightweighting”
§ Lightweight packages produce less
  waste than packages manufactured from
  heavyweight materials
  § Requires new designing and technolgies
    since lightweight material generally are not
    stronger
  § Softdrink manufacturers have manage to
    reduce PET up to 5%
NESTLE MINERAL WATER
Design for Reuse
Sustainable Paper Packaging
diverted 20 tons of plastic bags from
landfills two years after the launch of its
reusable grocery bag program.
Design for
Biodegradable
- use of natural fibers
- degradable polymers
(biopolymers)
 biopolymers)
Dell introduces packaging
   made from bamboo




               Packaging Digest, 11/17/2009
Coca-Cola begins global
 launch of PlantBottle




               Packaging Digest, 11/16/2009
USE OF
NANOMATERIALS
IN PACKAGING
§ bottles made with nanocomposites that minimize
  the leakage of carbon dioxide out of the bottle; this
  increases the shelf life of carbonated beverages
  without having to use heavier glass bottles or more
  expensive cans
§ food storage bins with silver nanoparticles
  embedded in the plastic. The silver nanoparticles
  kill bacteria from any food previously stored in the
  bins, minimizing harmful bacteria.
§ CONCERNS: Because the particles are
  so small, these materials might be able
  to migrate into food
§ Nanopartcles (eg. nanoCeO2 and TiO2)
  have been used to increase UV
  resistance in plastic packaging
§ Other nanomaterials have the
  potential to improve a variety of
  packaging-
  packaging-performance attributes
  such as oxygen and moisture
  blockage, ink or dye-free coloration
                   dye-
  and increased strength while
  lightweighting.
Use of Nanomaterials
INNOVATIVE NEW FIBERS
    FOR PACKAGING
    through Surface
    Functionalization/derivatization
§   Moisture stable
§   Breathable
§   Enhanced strength properties to allow for
    lightweighting
§   Paper foam packaging
§   Controlled diffusion packaging
Real problem with
sustainable paper
packaging in Malaysia is
Raw Material

Solution: Use Oil Palm
Biomass Fibers as raw
material
Any Burning
Questions?
 wanrosli@usm.my
ALEXANDER GRAHAM BELL
"Don't keep forever on the public
  road, going only where others
            have gone.
Leave the beaten track occasionally
      and dive into the woods.
You will be certain to find something
    you have never seen before.“
DESCRIPTION OF
       THE
ENVIRONMENTALL
    FRIENDLY
  TECHNOLOGY
   PROCESSES
ENVIRONMETALLY FRIENDLY
               TECHNOLOGY

  Oil Palm                   Pretreatment
                       1. Soaking
 Empty Fruit           2. Washing
                                   Oily substance removal

   Bunch               3. Mechanical process – silica
                          removal
  (In strand form)


  Unbleached              Pulping
EcoPalm Pulp™          Extended Soda
                       Anthraquinone

TCF Bleaching
1. Oxygen                     Bleached
2. Ozone                   EcoPalm Pulp™
3. Hydrogen Peroxide
STAGE 1:
PRETREATMENT OF
    RAW MATERIAL

 (i) Soaking
 (ii) Washing
 (iii) Mechanical process
EFBs are obtained following the extraction
of the palm oil, nevertheless, part of the oil still
remains, which, if not removed will cause
considerable reduction in pulp quality and its
subsequent products.

  Hence, the first step is minimizing the oil
content in the raw material
Fig. 1: The brown       Fig. 2: The after washed
coloured      washed    and unwashed EFB fibre
water, suspected of     strands.
containing some oily
substance,     water-
soluble lignin, and
extractive
As with most non-woody material,
EFB also contains a substantial amount
of 1% silica, which can increase liquor
viscosity thus posing problems in
chemical recovery. In addition, its
presence could cause abrasion of
metals during papermaking and also
reduce paper quality.
Sustainable Paper Packaging
As part of the technology, a simple
mechanical      process     has    been
developed that could remove almost
80% of the silica present. It is
postulated that during this mechanical
treatment, the silica is dislodged from
the fiber surfaces as evident from the
scanning electron microscope pictures
(Fig. 3) and later washed out during
the washing stages
Plate 1: Initial surface of EFB (P)     Plate 2: Cracks attributable to
          with silica lodged            mechanical treatment as evident on Q




                                        Fig. 3: The Effect of
                                        Mechanical Treatment on
                                        EFB fiber
 Plate 3: Removal of metals by
 washing assisted dislodge of silica.
STAGE 2: PULPING
Pulping chemicals used:
                  used:
  sodium hydroxide and anthraquinone but
  with extensive modifications of the
  pulping parameters (henceforth called
  Extended Soda Anthraquinone Pulping)
  Either the cooking time for pulping or the
  pulping temperature is increased to
  provide extended delignification.
                   delignification.
STAGE 3:
BLEACHING
The brown color of unbleached pulp is
mainly associated with its lignin component.
                                  component.

To reach an acceptable brightness level, this
residual lignin has to be removed through a
series of bleaching sequences.
                    sequences.

Common bleaching chemicals today are
chlorine and chlorine dioxide, which has
been blamed for the environmental issues
created.
created.
Sequences and optimization of parameters
are of paramount importance for a
successful bleaching process; failure in
                          process;
either of these two aspects will contribute to
an inferior quality cellulose pulp resulting in
a low -grade end product.
  low-           product.

In tandem with global requirements, the
bleaching treatment put forward in this work
is of the following sequence: Oxygen (O),
                    sequence:
Ozone (Z) and Peroxide (P), with inclusion of
several chemicals to increase the reactivity
of each step. In addition the pulp was
          step.
washed in between the processes.
                      processes.
Any Burning
Questions?
 wanrosli@usm.my
Sustainable Paper Packaging
Sustainable Paper Packaging
Load-elongation curve of paper at different
humidities. The ends of the curves
correspond to specimen rupture
Diagrammatic representation of changes in
paper properties with relative humidities
Effect of Recycling on paper properties
H2O
WATER


O---H---O

H BOND




            106
Other potential uses of
oil palm biomass
TOTAL POTENTIAL UTILIZATION

                           OIL PALM BIOMASS (OPB)



                                 OPB PULP                        Black liquor



  Polymer                        Unbleached
                                                    Bleached/             Cellulose
  Composite                      Pulp
                                                    Diss. Pulp            Derivatives


Thermoplastic      Thermoset       Rubber
                                                 Lignin          Glaze material
      Effluent treatment
      using AC
                                 Lignin based Products             Glaze products


  Soda lignin         Vanillin       Oil-water            Anti corrosion
                                     Emulsion             agent
Cellulose Derivatives
 • Cellulose Acetate (CA)
 • Carboxymethyl cellulose (CMC)
 • Cellulose Phosphate
BIOMEDICAL
APPLICATIONS
§ cellulose acetate an acetylated cellulose used as
  a hemodialyzer membrane.
§ oxidized cellulose an absorbable oxidation
  product of cellulose, used as a local haemostatic
              cellulose,
  (also in wound dressing)
§ Carboxymethylcellulose a substituted cellulose
  polymer of variable size, used as the sodium or
  calcium salt as a pharmaceutical suspending agent,
  tablet excipient, and viscosity-increasing agent; the
                         viscosity-
  former is also used as a laxative.
                             laxative.
§ cellulose sodium phosphate an insoluble,
  nonabsorbable cation exchange resin prepared from
  cellulose; it binds calcium and is used to prevent
  formation of calcium-containing renal calculi.
                 calcium-
§ cellulose phosphate an insoluble material which
  has the potential to be used in orthopedic
  applications
§ Microcrystalline (MMC), is widely used in the
  pharmaceutical and food industries for several
  applications and enjoys the generally recognized as safe
  (GRAS) status
§ Cellulose viscose sponges have also been proposed
  as implantable tissue matrices for connective tissue
  regeneration.
§ Cellulose regenerated by the viscose process has
  also been investigated as an implantable material in
  orthopedic surgery, as a sealing material for the femoral
  component in hip prostheses, in place of acrylic cement.
CONCLUSIONS
§ Pulp mills based on the oil palm biomass
  are attractive to our palm oil industry
  because of several benefits.
  v Firstly, it will help to decrease rural
    depopulation
  v Secondly, there will be a reduction in the outflow
    of the currency due to fewer imports of paper
    and paper products.
  v Thirdly, it will help create new pulp and paper
    technologies and also new products which are
    currently being developed in our laboratories.
  v And, finally, it will create economic growth for
    the nation.
§ However, the use of conventional technology in
  processing oil palm biomass is of little interest due
  to the overwhelming environmental problems
  generated.
   v Thus to promote sustainable development, the
     pulp mill based on oil palm biomass should be
     able to operate free from sulphur and chlorine
     and its derivatives and the cellulose pulp
     produced should be of comparable quality to its
     woody counterparts.
§ The proposed environmentally friendly technology
  consisting of the three or five sequences meets
  these demands and probably even more.
§ Sustainable pulp production from oil palm biomass
  using the proposed environmentally friendly
  technology is definitely close to reality.
Being both a tree-free and
                   tree-
  hazardous-
  hazardous-free paper, this
  product (EcoPalm Paper™)
             (EcoPalm Paper™)
fulfills itself as one of the truly
environmentally friendly paper
            of our time.
Sustainable Paper Packaging
TQ

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Sustainable Paper Packaging

  • 1. SUSTAINABLE PAPER PACKAGING (PEMBUNGKUSAN KERTAS LESTARI) INTERNATIONAL SYMPOSIUM ON CURRENT ADVANCEMENT AND RESEARCH IN TEXTILE & PACKAGING TECHNOLOGY Wan Rosli Wan Daud Universiti Sains Malaysia
  • 2. Packaging falls into a number of categories: § Primary –packaging in contact with the product. § Secondary –‘outers’ which hold a number of packed products as a unit of say 10 or 12. § Tertiary –stretch wrapped pallets which hold perhaps 100 ‘outers’ or cases.
  • 3. PACKAGING Purposes: § Contain § Inform § Protect § Transport § Display
  • 4. PACKAGING put in another way: § is a means of ensuring safe delivery of a product to the ultimate user in a sound condition at a minimum overall cost § Science § Art § Technology
  • 5. ELEMENTS OF PACKAGING: § Materials § Design - address the issue of wastage - under-packaging cause damage and spoilage to contents - over-packaging wasting resources - goal is “RIGHT SIZE” packaging - packaging design software eg PIQET, Australia (Packaging Impact Quick Evaluation Tool); TOPS, USA (Total Optimization ); Packaging Software)
  • 6. Materials § Metals (aluminum & steel) § Glass § Polymers (Plastics) § Wood/Composites § Paper
  • 8. § Measures taken by various sectors to allay fears of sustainability centers around the traditional waste management hierarchy – 3R’s § Reduction § Reuse § Recycling/Recovery
  • 10. Sustainable Development Entered the public debate after the World Commission on Env. And Dev. Published their landmark report “OUR COMMON FUTURE “ in 1987 Reiterates the most often quoted definition (Brundtland Commission (United nations, 1983): “meets the needs of the present without compromising the ability of future generations to meet their own needs” needs”
  • 11. Sustainable packaging § Is beneficial, safe & healthy for individuals and communities throughout its life cycle; § Meets market criteria for performance and cost; § Is sourced, manufactured, transported, and recycled using renewable energy; § Optimizes the use of renewable or recycled source materials; § Is manufactured using clean production technologies and best practices; § Is made from materials healthy in all probable end-of- life scenarios; § Is physically designed to optimize materials and energy; § Is effectively recovered and utilized in biological and/or industrial closed loop cycles. www.sustainablepackaging.org
  • 12. Sustainable Development Most often quoted definition (Brundtland Commission (United nations, 1983): “meets the needs of the present without compromising the ability of future generations to meet their own needs” needs” Can be conceptually broken into three constituent parts: § environment, § economic and § social
  • 13. Sustainable Development Model of sustainable development: at the confluence of three constituent parts
  • 14. § With paper packaging there has never been an issue regarding sustainability – its always sustainable § WHY?
  • 16. Environmental Dependable § Made from renewable resources § One of the highest recovery rate of all packaging - almost 60% of paper are recycled § Almost total compostable
  • 17. Socially Dependable § Produced by manufacturers who practised high safety standards – ISO 9000 series § Charitable donations from companies to community § Industry involve educating the public the importance of recycling through school and outreach programs
  • 18. Economically Dependable § Contributing to the nations’ economy § Creation of jobs
  • 19. So what’s the problem? §Paper packaging consumption steadily rising over the years
  • 20. CONSUMPTION OF CORRUGATING MEDIUM IN MALAYSIA X000 TONNES 600 400 200 0 1992 1996 2000 2004 2008 YEAR Asian paper Packaging Historical Data, 2009
  • 21. §Problems in sourcing of and quality of raw material §Issue of Raw Material Sustainability
  • 22. Social Environmental sustainability sustainability SUSTAINABLE PAPER PACKAGING Raw material Economic sustainability sustainability FACTORS IMPACTING SUSTAINABLE PAPER PACKAGING, AND THEIR INTERDEPENDENCE
  • 24. Raw material for paper and paper packaging are the cellulose fibers § hygroscopic property (absorb moisture)
  • 25. Malaysia being in the equatorial region has high humidity § effect on paper strength properties
  • 26. How to overcome this problem? Yield Pt. NSSC KLB UKP Load 1 Stretch High Humidity Resistance of Various Pulps
  • 27. Another critical issue relating to raw material sustainability is Quality of raw material § Basically most of all paper packaging in Malaysia uses recycled fibers § Problem of strength
  • 34. § Loss of swelling ability of cellulosic fiber upon drying § due to the closure of pore spaces in the cell walls, plus § the inability of many of the pores to reopen if the fibers are rewetted
  • 35. WETTING A B DRYING Progressive swelling of fibre wall: from A to D Progressive shrinkage of fibre wall: from D to A C D 35
  • 36. DRIED FIBRES NEVER-DRIED FIBRES CHEMICAL PULP FIBRES 36
  • 37. Factors that influence Hornification § High-yield pulps, such as thermomechanical pulp (TMP), appear to be much less susceptible to changes when they are dried
  • 38. MECHANICAL PULPS CHEMICAL PULPS 38
  • 39. RESTORATIVE TREATMENTS a) Refining b) Fractionation c) Chemical additives § Starches § Polyacrylamides (PAM) d) Blending with virgin fibers
  • 40. Where do we get the virgin fibers from?
  • 41. MALAYSIA - SOURCES OF IMPORTED VIRGIN PULP Others, 11% Chile, 4% Canada, 5% Thailand, 7% USA, 59% New Zealand, 14% Importation of wood pulp to Malaysia is dominated by USA Total imports of wood pulp in 2002 is ca. RM138 Million with a growth of 5.6% compared to 2001
  • 42. “Let the building and other critically wood- wood- dependent industries use wood. Pulp and paper industry should opt to non- non-wood and wastes for sustainability” sustainability” Ako Norlander, Appita J. 2008
  • 43. Pulp from oil palm biomass as reinforcement in recycled fibers
  • 44. Palm oil constitutes only 10% of the palm production while the rest is biomass The biomass (waste residues) generated from this industry throughout harvesting and processing activities as well as during replanting is enormous § Estimated to be 60-100 million tonnes (wet) 60- Forms of waste residues: § Empty fruit bunches (EFB) § Fronds § Trunks
  • 45. BIOMASS/PRODUCTS FROM OIL PALM TREE Fronds Empty Fruit Bunch Fresh Fruit Bunch Crude Palm Oil Oil Palm Tree Trunk
  • 46. § An estimation, based on a planted area of 25,700 million m2, and a production rate of dry oil palm biomass of 20,336 kg per 10,000 m2 per year, shows that Malaysian palm oil industry produced approximately 56.9 million tonnes of lignocellulosic biomass in 2000. § Taking into account the proportion of useful fibrous elements that can be extracted from various oil palm components, an overall recovery rate of 75% and a pulp yield of 45%, the net useful bleached pulp would amount to about 14.8 million tonnes § VERY SUSTAINABLE
  • 47. OCC FIBER + EFB PULP = PAPER ROLL
  • 48. EFFECT ON BURST STRENGTH 160 140 Burst Strength kPa 120 100 80 60 40 20 0 0% 20% 40% 60% 80% 100% Pulp addition
  • 49. EFFECT ON RING CRUSH 60 RING CRUSH (N) 40 20 0 0% 20% 40% 60% 80% 100% % Pulp addition
  • 51. For a sustainable pulp production § other than a continuous supply and availability of raw materials, § the processes involved in the production of pulp and paper have to be environmentally friendly § Nevertheless, process(es) must be economic viable, if not it will just be an academic study, without having much impact on the society in the long term
  • 52. Kraft, Sulfite Pulping Raw material Unbleached Pulp Cl2 & derivatives Bleached Pulp PRODUCTION OF PULP
  • 53. These processes (esp. bleaching) are known to generate serious environmental drawbacks § Chlorine reacts with lignin, to form chlorinated organic compounds (e.g., dioxin) dioxin) o believed to be carcinogenic to humans based on results of laboratory studies with animals § The presence of these chlorinated compounds has also been linked to adverse ecological effects on wildlife in receiving waters
  • 54. § And to reduce these shortcomings, it is imperative that alternative methods which are cleaner and environmentally friendly are used § ENVIRONMENTALLY SUSTAINABLE
  • 55. ENVIRONMENTAL SUSTAINABILITY § Environmental sustainability is defined as the ability of the environment to continue to function properly indefinitely § Goal to minimize environmental degradation, and to halt and reverse the processes they lead to § Clean Technologies for Pulp Production
  • 57. “manufacturing processes or product technologies that reduce pollution or waste, energy use, or material use in comparison to the technologies that they replace” process(es) must be economic viable, if not it will just be an academic study, without having much impact on the society in the long term environmentally friendly – SULFUR FREE PULPING AND CHLORINE FREE BLEACHING
  • 58. CLEAN TECHNOLOGY FOR PULP PRODUCTION Oil Palm Pretreatment 1. Soaking Empty Fruit 2. Washing Oily substance removal Bunch 3. Mechanical process – silica removal (In strand form) Unbleached Pulping EcoPalm Pulp™ Extended Soda Anthraquinone TCF Bleaching 1. Oxygen Bleached 2. Ozone EcoPalm Pulp™ 3. Hydrogen Peroxide
  • 59. COMPARISON OF PAPER PROPERTIES FROM OIL PALM EFB AND COMMERCIAL HARDWOOD PULPS (UNBLEACHED) Tensile Tear Index Burst Index (mN.m2g-1) Index (Nm/g) (kPa.m2g-1) Commercial 13.21 3.14 1.0 Hardwood Empty Fruit 15.81 3.85 1.20 Bunch
  • 60. COMPARISON OF PAPER PROPERTIES FROM OIL PALM EFB AND COMMERCIAL HARDWOOD PULPS (BLEACHED) 25 20 15 10 5 0 Tensile Index Tear Index Burst Index Brightness (Nm/g) (mN.m2g-1) (kPa.m2g-1) (x 10%) Commercial Hardwood Pulp 19.55 2.6 1.4 8.43 Empty Fruit Bunch Pulp 20.41 2.72 2.46 8.33
  • 61. POTENTIAL PRODUCT APPLICATION(S) Unbleached virgin pulp (Unbleached EcoPalm Pulp™) which can be used in Pulp™) full or mixed with wastepaper depending on the final product Bleached virgin pulp (Bleached EcoPalm Pulp™) which can be used in Pulp™) the production of writing and printing paper
  • 62. Yield Pt. NSSC KLB UKP Load 1 Stretch High Humidity Resistance of Various Pulps
  • 63. MECHANICAL PULPS CHEMICAL PULPS 63
  • 64. Alkaline Peroxide Mechanical Pulping (APMP) process involves the impregnation of the chips with an alkaline peroxide bleach liquor in one or more steps prior to atmospheric refining, hence combining pulping and bleaching in a single operation
  • 65. Attractive Features of APMP § High yield (85% on average), compared to 50% or lower yield of chemical pulping § High brightness – use of peroxide § Can also be use for newsprint
  • 67. Packaging Source Reduction § Avoid unnecessary components § Eg: Toothpaste boxes have been eliminated in countries with strict waste laws § Reduce amount of material § Eg. Nike
  • 68. Nike
  • 69. “Lightweighting” § Lightweight packages produce less waste than packages manufactured from heavyweight materials § Requires new designing and technolgies since lightweight material generally are not stronger § Softdrink manufacturers have manage to reduce PET up to 5%
  • 73. diverted 20 tons of plastic bags from landfills two years after the launch of its reusable grocery bag program.
  • 74. Design for Biodegradable - use of natural fibers - degradable polymers (biopolymers) biopolymers)
  • 75. Dell introduces packaging made from bamboo Packaging Digest, 11/17/2009
  • 76. Coca-Cola begins global launch of PlantBottle Packaging Digest, 11/16/2009
  • 78. § bottles made with nanocomposites that minimize the leakage of carbon dioxide out of the bottle; this increases the shelf life of carbonated beverages without having to use heavier glass bottles or more expensive cans § food storage bins with silver nanoparticles embedded in the plastic. The silver nanoparticles kill bacteria from any food previously stored in the bins, minimizing harmful bacteria. § CONCERNS: Because the particles are so small, these materials might be able to migrate into food
  • 79. § Nanopartcles (eg. nanoCeO2 and TiO2) have been used to increase UV resistance in plastic packaging § Other nanomaterials have the potential to improve a variety of packaging- packaging-performance attributes such as oxygen and moisture blockage, ink or dye-free coloration dye- and increased strength while lightweighting.
  • 81. INNOVATIVE NEW FIBERS FOR PACKAGING through Surface Functionalization/derivatization § Moisture stable § Breathable § Enhanced strength properties to allow for lightweighting § Paper foam packaging § Controlled diffusion packaging
  • 82. Real problem with sustainable paper packaging in Malaysia is Raw Material Solution: Use Oil Palm Biomass Fibers as raw material
  • 85. "Don't keep forever on the public road, going only where others have gone. Leave the beaten track occasionally and dive into the woods. You will be certain to find something you have never seen before.“
  • 86. DESCRIPTION OF THE ENVIRONMENTALL FRIENDLY TECHNOLOGY PROCESSES
  • 87. ENVIRONMETALLY FRIENDLY TECHNOLOGY Oil Palm Pretreatment 1. Soaking Empty Fruit 2. Washing Oily substance removal Bunch 3. Mechanical process – silica removal (In strand form) Unbleached Pulping EcoPalm Pulp™ Extended Soda Anthraquinone TCF Bleaching 1. Oxygen Bleached 2. Ozone EcoPalm Pulp™ 3. Hydrogen Peroxide
  • 88. STAGE 1: PRETREATMENT OF RAW MATERIAL (i) Soaking (ii) Washing (iii) Mechanical process
  • 89. EFBs are obtained following the extraction of the palm oil, nevertheless, part of the oil still remains, which, if not removed will cause considerable reduction in pulp quality and its subsequent products. Hence, the first step is minimizing the oil content in the raw material
  • 90. Fig. 1: The brown Fig. 2: The after washed coloured washed and unwashed EFB fibre water, suspected of strands. containing some oily substance, water- soluble lignin, and extractive
  • 91. As with most non-woody material, EFB also contains a substantial amount of 1% silica, which can increase liquor viscosity thus posing problems in chemical recovery. In addition, its presence could cause abrasion of metals during papermaking and also reduce paper quality.
  • 93. As part of the technology, a simple mechanical process has been developed that could remove almost 80% of the silica present. It is postulated that during this mechanical treatment, the silica is dislodged from the fiber surfaces as evident from the scanning electron microscope pictures (Fig. 3) and later washed out during the washing stages
  • 94. Plate 1: Initial surface of EFB (P) Plate 2: Cracks attributable to with silica lodged mechanical treatment as evident on Q Fig. 3: The Effect of Mechanical Treatment on EFB fiber Plate 3: Removal of metals by washing assisted dislodge of silica.
  • 96. Pulping chemicals used: used: sodium hydroxide and anthraquinone but with extensive modifications of the pulping parameters (henceforth called Extended Soda Anthraquinone Pulping) Either the cooking time for pulping or the pulping temperature is increased to provide extended delignification. delignification.
  • 98. The brown color of unbleached pulp is mainly associated with its lignin component. component. To reach an acceptable brightness level, this residual lignin has to be removed through a series of bleaching sequences. sequences. Common bleaching chemicals today are chlorine and chlorine dioxide, which has been blamed for the environmental issues created. created.
  • 99. Sequences and optimization of parameters are of paramount importance for a successful bleaching process; failure in process; either of these two aspects will contribute to an inferior quality cellulose pulp resulting in a low -grade end product. low- product. In tandem with global requirements, the bleaching treatment put forward in this work is of the following sequence: Oxygen (O), sequence: Ozone (Z) and Peroxide (P), with inclusion of several chemicals to increase the reactivity of each step. In addition the pulp was step. washed in between the processes. processes.
  • 103. Load-elongation curve of paper at different humidities. The ends of the curves correspond to specimen rupture
  • 104. Diagrammatic representation of changes in paper properties with relative humidities
  • 105. Effect of Recycling on paper properties
  • 107. Other potential uses of oil palm biomass
  • 108. TOTAL POTENTIAL UTILIZATION OIL PALM BIOMASS (OPB) OPB PULP Black liquor Polymer Unbleached Bleached/ Cellulose Composite Pulp Diss. Pulp Derivatives Thermoplastic Thermoset Rubber Lignin Glaze material Effluent treatment using AC Lignin based Products Glaze products Soda lignin Vanillin Oil-water Anti corrosion Emulsion agent
  • 109. Cellulose Derivatives • Cellulose Acetate (CA) • Carboxymethyl cellulose (CMC) • Cellulose Phosphate
  • 111. § cellulose acetate an acetylated cellulose used as a hemodialyzer membrane. § oxidized cellulose an absorbable oxidation product of cellulose, used as a local haemostatic cellulose, (also in wound dressing) § Carboxymethylcellulose a substituted cellulose polymer of variable size, used as the sodium or calcium salt as a pharmaceutical suspending agent, tablet excipient, and viscosity-increasing agent; the viscosity- former is also used as a laxative. laxative. § cellulose sodium phosphate an insoluble, nonabsorbable cation exchange resin prepared from cellulose; it binds calcium and is used to prevent formation of calcium-containing renal calculi. calcium-
  • 112. § cellulose phosphate an insoluble material which has the potential to be used in orthopedic applications § Microcrystalline (MMC), is widely used in the pharmaceutical and food industries for several applications and enjoys the generally recognized as safe (GRAS) status § Cellulose viscose sponges have also been proposed as implantable tissue matrices for connective tissue regeneration. § Cellulose regenerated by the viscose process has also been investigated as an implantable material in orthopedic surgery, as a sealing material for the femoral component in hip prostheses, in place of acrylic cement.
  • 114. § Pulp mills based on the oil palm biomass are attractive to our palm oil industry because of several benefits. v Firstly, it will help to decrease rural depopulation v Secondly, there will be a reduction in the outflow of the currency due to fewer imports of paper and paper products. v Thirdly, it will help create new pulp and paper technologies and also new products which are currently being developed in our laboratories. v And, finally, it will create economic growth for the nation.
  • 115. § However, the use of conventional technology in processing oil palm biomass is of little interest due to the overwhelming environmental problems generated. v Thus to promote sustainable development, the pulp mill based on oil palm biomass should be able to operate free from sulphur and chlorine and its derivatives and the cellulose pulp produced should be of comparable quality to its woody counterparts. § The proposed environmentally friendly technology consisting of the three or five sequences meets these demands and probably even more. § Sustainable pulp production from oil palm biomass using the proposed environmentally friendly technology is definitely close to reality.
  • 116. Being both a tree-free and tree- hazardous- hazardous-free paper, this product (EcoPalm Paper™) (EcoPalm Paper™) fulfills itself as one of the truly environmentally friendly paper of our time.
  • 118. TQ