Performing Department
(N/A)
Non Technical Summary
Online sales in U.S.A. is expected to grow to 23.6% of total sales by 2025, with estimated revenue of $ 1.2 trillion, and as a result, demand for the packaging material is also increasing. Currently, packaging is made with either cardboard or polyethylene. Though cardboard is eco-friendly and sustainable, there are made with wood pulp, leading to deforestation, while 86% polyethylene packaging ends up in landfill. With the global push towards sustainiblity, there is a industry-defined need for a sustainable packaging material that is curbside-recyclable/compostable, while generating a low-carbon footprint. We propose to develop a sustainable composite packaging material using non-woven natural fiber as reinforcement material and a water soluble binding matrix that is home-compostable with properties suitable for e-commerce. Flax and hemp fibers are abundant, under-utilized and are a byproduct of seed cultivation, but possess mechanical properties ideal for packaging. Flax/hemp fibers will used a reinforcement fiber in a water-soluble matrix like polyvinyl alcohol (PVA) to form a composite. To make this composite weather-resistant, an optimum coating material will be identified and applied. The coated-composite will be subjected to mechanical and environmental stress tests to prove its feasibility in packaging environments. Composite's manufacturing scalability and ability to be formed into shapes relevant to packaging will also be evaluated. Sustainability of coated-composite will be determined through compostablity and carbon-footprint analysis. Research findings are expected to offer flax/hemp farmers an additional revenue turning what's currently a byproduct into a profitable commodity, thereby supporting the economic development of rural and tribal communities.
Animal Health Component
0%
Research Effort Categories
Basic
10%
Applied
60%
Developmental
30%
Goals / Objectives
The long-term goal of this research is to increase the use of sustainable bio-based low-carbon footprint flexible packaging material for e-commerce that is compostable using under-utilized agricultural byproducts that will add value to the agricultural economy of united states. Our short-term goal is to develop a sustainable packaging material using non-woven natural fiber as reinforcement material and a water activated/biodegradable matrix as a binder with properties suitable for e-commerce.
Project Methods
Task/SubtaskMilestonesObjective 1:Determination of the optimum material composition for the reinforcement fiber and binding matrix of the packing material1.1Identification and characterization of fiber propertiesFibers with properties applicable to packaging are identified1.2Identification and characterization of binding matrixBinding matrices that is water soluble and compatible with fibers are identified1.3Mechanical testing of the identified compositionsComposite material meets ASTM E1148, D790, D624, D638 standardsObjective 2:Identification of appropriate methods for manufacturing the composite in suitable shapes and sizes for use in packaging2.1Determination of feasible manufacturing methodsAble to fabricate the composite with thickness (< 2 mm) and shapes (sheets, cylinders)2.2Identification of critical process parametersProcess parameters that have a significant effect (α = 0.05) on the mechanical properties of composite are determinedObjective 3:Determination of coating material and the method of coating for making composites weather resistant3.1Identification of feasible materials for the coatingCoating material that is weather resistant and water soluble is identified3.2Determination of coating methodOptimized coating method and thickness identified3.3Evaluation of the weather resistance and durablityCoated composite is able to endure the weather and handling tests (ASTM ASTM E1148, D790, D624, D638 standards, QUV, thermal shock)Objective 4:Determination of sustainability and economic viability of the developed composite for e-commerce application4.1Determination of compostability and carbon-foot printComposite is compostable (ASTM D6400) and carbon footprint is estimated4.2Determination of potential economic impactEstimated to generate additional revenue for the U.S. agriculture.