Progress 07/01/24 to 06/30/25
Outputs
Target Audience:During this reporting period, the project reached several key audiences through academic involvement, stakeholder engagement, and formal presentations. Our efforts targeted both technical and agricultural communities involved in sustainable material development and bioeconomy applications: Undergraduate and Graduate Students Students from the Departments of Mechanical Engineering, Materials and Nanotechnology, and Environmental Engineering at North Dakota State University (NDSU) participated in laboratory research. These students were directly involved in material fabrication, mechanical testing, and characterization studies, gaining valuable experience in sustainability-focused research and bio-based materials. Faculty Researchers and Academic Peers The project was shared with faculty members across disciplines, including polymer science, bioproducts engineering, agricultural economics, and coatings technology. Discussions centered on optimizing composite properties and integrating life cycle analysis into future phases of the research. North Dakota Soybean Council (NDSC) A formal presentation of this research was made to the North Dakota Soybean Council, focusing on the potential of incorporating soy-derived biopolymers (such as plasticized starch and modified seed oils) into compostable packaging materials. The council's feedback provided insights into material sourcing, rural market value, and potential funding avenues to scale development. This engagement also highlighted the importance of creating value-added uses for agricultural byproducts and aligned well with the council's strategic focus on sustainability and innovation. Flax and Hemp Growers in North Dakota Informal outreach was initiated with flax and hemp producers regarding the use of underutilized fibers (short tow flax and hemp hurds) as reinforcement fillers. These stakeholders expressed interest in the potential to develop new revenue streams from agricultural residues, strengthening the local bioeconomy. Sustainability-Focused Campus and Local Organizations Project outcomes and early-stage findings were shared during campus sustainability events and research showcases at NDSU. These events engaged students, faculty, and community members interested in sustainable packaging alternatives and reducing plastic waste. Broader Research and Innovation Community Informal discussions with researchers at peer institutions and within entrepreneurship-focused student groups explored collaboration opportunities and commercialization pathways for bio-based composite packaging. By reaching diverse audiences including commodity councils, farmers, researchers, and students, this project has laid the foundation for future adoption and scale-up. In the next reporting period, targeted efforts will expand to: Commercial e-commerce packaging companies USDA extension and rural development networks State-level sustainability policymakers Industry and investor partners in green packaging solutions Changes/Problems:During this reporting period, the project has not encountered any major disruptions but has undergone a few key adjustments to improve material compatibility, address experimental limitations, and ensure progress toward project goals. The following changes were made: 1.Change in Matrix Material from PVA to Alginate and Expansion to Other Biopolymers While the original proposal identified polyvinyl alcohol (PVA) as the primary biodegradable matrix, experimental results indicated that sodium alginate provided superior dispersion within the natural flax fiber mats, along with better film-forming behavior and biodegradability. Consequently, alginate was adopted as the primary matrix in initial fabrication trials. Additionally, based on industry benchmarking and sustainability criteria, the team plans to expand matrix screening to include plasticized starches and modified seed oil-based resins, both of which offer desirable environmental and mechanical performance properties. These substitutions remain aligned with the project's goals of water-activated, compostable packaging and are expected to improve scalability and consumer safety. 2.Optimization of Fiber Processing Early trials using non-woven flax fiber mats showed variable mat densities, which affected uniformity in composite sheets. To improve consistency, a manual pre-compaction step and controlled fiber layering were introduced to standardize fiber loading. This adjustment has enhanced mechanical reliability and will support repeatability in future scaled production. 3.Extended Drying and Cure Times for Composite Sheets Composite sheets formed with alginate and glycerol as plasticizer required significantly longer drying times under ambient lab conditions (up to 4-6 days instead of the projected 2-3 days). As a response, drying trials under controlled temperature and airflow are being implemented to optimize curing rates without compromising biodegradability. 4.Delay in Coating Trials Although coating studies using alkyd and seed oil-derived biodegradable resins were scheduled early in the timeline, sourcing delays and focus on base composite optimization led to a postponement. These coating trials are now planned for the upcoming reporting period and will be prioritized to assess weather resistance, water activation potential, and adhesion to the composite substrate. 5.Unavailability of Environmental Testing Chamber Limited access to the Q-Lab QUV chamber for accelerated UV and moisture testing temporarily delayed durability trials. Coordination is in progress to utilize equivalent facilities within a partnering department. No major impact on overall timeline is expected. 6.Refinement of Testing Protocols for E-commerce Relevance Based on stakeholder feedback and pilot mechanical results, new test protocols--such as drop impact testing, coating adhesion with commercial packaging tape, and thermal shock simulation--were added to ensure practical relevance for e-commerce use cases. These additions strengthen the original methodology and align with packaging industry expectations. What opportunities for training and professional development has the project provided?This project has created several hands-on and academic development opportunities for both undergraduate and graduate students at North Dakota State University (NDSU), particularly within the Departments of Mechanical Engineering, Environmental Engineering, and Materials and Nanotechnology. Specific opportunities include: Hands-On Research Experience in Sustainable Materials Students were actively involved in fabricating biodegradable composite materials using non-woven flax fibers and sodium alginate. This included tasks such as: Fiber mat preparation and matrix mixing Cold pressing of composite sheets and molds Observing and documenting drying behavior and form stability These activities provided practical experience in bio-based composite fabrication, a field of growing importance in sustainable product development. Training in Experimental Design and Data Collection The team received training in basic experimental design principles to ensure repeatability and control during material synthesis. Students learned to document process variables (e.g., pressure, drying time, composition ratios) and interpret qualitative performance outcomes. Exposure to ASTM Standards and Testing Protocols Although mechanical testing is planned for the next reporting period, students were introduced to relevant ASTM protocols for tensile, flexural, and environmental testing. This early exposure builds familiarity with standardized material evaluation processes used in industry and research. Presentation and Communication Skills Development Students were involved in preparing and contributing to a formal presentation delivered to the North Dakota Soybean Council. This experience helped them develop skills in technical communication, stakeholder engagement, and tailoring scientific content for non-academic audiences. Professional Mentorship and Interdisciplinary Collaboration The project enabled students to interact with faculty members across engineering, coatings science, and agricultural economics, offering a holistic perspective on how materials science intersects with sustainability, rural development, and commercialization. In summary, the project provided participants with valuable training in experimental techniques, materials handling, communication, and interdisciplinary collaboration--all essential skills for future careers in sustainability-driven research, industry, or academia. How have the results been disseminated to communities of interest?During this reporting period, the project's early-stage findings and goals were disseminated through targeted outreach to academic, agricultural, and research communities. These efforts helped initiate collaborative dialogue, gather feedback, and build momentum for future development. Specific dissemination activities included: Presentation to the North Dakota Soybean Council (NDSC) The research team presented the project to the North Dakota Soybean Council, focusing on the potential application of soy-derived biopolymers (e.g., plasticized starch and modified seed oils) as sustainable matrices in bio-based packaging. This presentation sparked valuable discussions about sourcing, value-added use of agricultural byproducts, and regional bioeconomy potential. Internal Research Presentations and NDSU Showcases The project was shared at internal research meetings and sustainability-themed events at North Dakota State University. These events engaged faculty, graduate students, and research groups working in materials science, packaging, and agricultural engineering. These sessions contributed to knowledge-sharing, feedback collection, and interdisciplinary exposure. Informal Outreach to Flax and Hemp Growers Informal discussions were conducted with flax and hemp producers in North Dakota to assess interest in supplying underutilized fiber residues for composite development. These interactions served to inform the producers about the project's objectives and gauge the viability of fiber sourcing from a practical and economic standpoint. Upcoming Conference Presentation at ISMR 2025 The project has been accepted for oral presentation at the International Symposium on Materials Research (ISMR) 2025, scheduled for July 15, 2025. This platform will allow the team to share findings with a broader scientific and industrial audience, gain visibility in the sustainable materials research community, and establish potential collaborative or translational opportunities. Student Engagement and Peer Learning Students involved in the research have shared their work through informal lab discussions, poster preparation, and team meetings. These interactions have helped spread awareness of bio-based material innovation and foster a culture of sustainability-focused inquiry among their peers. As the project advances into its next phase, dissemination efforts will expand to include formal publications, industry stakeholder outreach, and coordination with USDA extension networks. These actions will ensure continued alignment with project goals and increased impact across research, industry, and rural development communities What do you plan to do during the next reporting period to accomplish the goals?During the next reporting period, we plan to build upon our initial fabrication and prototyping efforts by focusing on material optimization, environmental performance testing, and early-stage sustainability analysis. These activities will directly advance our short-term goal of developing a viable, compostable packaging material for e-commerce and continue progress toward the long-term objective of supporting a sustainable, bio-based packaging economy. Specific planned actions include: Matrix and Fiber Composition Optimization Evaluate additional matrix materials, including plasticized starch and modified seed oils, in combination with flax fibers to identify formulations with improved flexibility, weather resistance, and processing ease. Conduct compatibility tests (e.g., wettability, adhesion, curing time) between fibers and newly introduced matrices using standardized methods such as ASTM D7490 and E1148. Coating Trials and Environmental Resistance Testing Begin coating studies using biodegradable alkyd resins and seed-oil-based coatings. These coatings will be applied to previously fabricated flax-alginate composites. Evaluate different application techniques (e.g., spraying, dipping, UV curing) to determine optimal coating methods. Perform water exposure tests, thermal shock tests, and UV stability assessments to determine durability and shelf-life potential of coated composites. Mechanical Property Testing Conduct a full suite of ASTM-based mechanical tests, including: Tensile strength (ASTM D638) Flexural strength (ASTM D790) Tear resistance (ASTM D624) Impact resistance (drop tower test) Analyze how different fabrication parameters and material compositions influence these properties to identify optimal design space for e-commerce packaging applications. Sustainability and Economic Viability Assessment Initiate compostability testing (ASTM D6400) to evaluate the degradation profile of coated and uncoated composite sheets in controlled aerobic environments. Launch a preliminary carbon footprint assessment using the GREET model, focusing on emissions and energy use from material sourcing through composite fabrication. Begin compiling data for techno-economic analysis of the new packaging material in comparison to conventional PE-based alternatives. Dissemination and Conference Presentation Present current findings at the International Symposium on Materials Research (ISMR) 2025 on July 15. Continue outreach to potential collaborators, including packaging companies, agricultural cooperatives, and industry partners interested in compostable material development. Prepare draft material for peer-reviewed publication and USDA technical briefs. Scale-Up Planning and Design of Experiments (DoE) Implement a structured design of experiments (DoE) framework to study the effects of pressing time, pressure, and fiber-to-matrix ratio on final product performance. Begin evaluating feasibility of pilot-scale production methods, such as vacuum-assisted compression molding or hot pressing, to move toward practical implementation. These planned activities are designed to solidify the technical foundation of the project, validate environmental claims, and begin building the framework necessary for industry engagement and commercialization.
Impacts
What was accomplished under these goals?
During this reporting period, substantial progress was made toward the short-term goal of developing a sustainable, compostable packaging material using non-woven natural fibers and biodegradable matrices. The following accomplishments were achieved: Fabrication of Natural Fiber-Based Composites Non-woven flax fiber mats were sourced and processed into composite sheets using sodium alginate as the primary biodegradable matrix. These fiber-matrix composites were fabricated through cold pressing, resulting in flexible sheets that could be shaped into packaging-relevant forms such as cups and cylindrical containers. This demonstrated the feasibility of forming biodegradable composite materials using agricultural residues. Shift from PVA to Alginate and Future Matrix Plans While the original proposal included polyvinyl alcohol (PVA) as the primary matrix, early experimentation revealed sodium alginate offered better environmental performance, ease of use, and biodegradability. As a result, alginate was used for initial composite development. Future work will explore plasticized starch and modified seed oils to improve mechanical performance, water resistance, and processing behavior, in alignment with the project's sustainability objectives. Cold Pressing Method and Form Factor Trials Using low-pressure cold pressing and shaped molds, the composites were successfully formed into usable three-dimensional structures. This confirms the material's ability to be shaped into packaging formats without requiring high energy input or complex equipment. Cylindrical shapes were maintained after drying, supporting the feasibility for low-load e-commerce shipping. Process Optimization Based on Drying Observations A key observation during fabrication was that alginate-based composites required 3-5 days of drying time, longer than originally anticipated. This prompted the team to begin testing controlled drying conditions and pre-compaction of fiber mats to improve uniformity and reduce variability in curing. These process adjustments are critical for future scalability and standardization. Stakeholder Engagement: North Dakota Soybean Council Presentation The project team presented the research to the North Dakota Soybean Council, with discussions focused on the integration of soy-based biopolymers into future matrix formulations. This engagement provided critical feedback on sourcing, agricultural economics, and end-use alignment with industry priorities. It also established early interest in collaborative development and commercialization. Preliminary Outreach to Agricultural Producers Informal conversations were initiated with flax and hemp growers in North Dakota, exploring opportunities to utilize crop residues (such as short tow flax and hemp hurds) as reinforcement fibers. These stakeholders showed interest in the potential for value-added applications of underutilized byproducts. The project successfully transitioned from concept to prototype development using flax fibers and alginate. Cold-pressed composites were fabricated and shaped, validating the initial approach. Key lessons on matrix selection and process improvements have been identified, laying the groundwork for mechanical testing, coating, and sustainability assessments in the next phase.
Publications
- Type:
Conference Papers and Presentations
Status:
Accepted
Year Published:
2025
Citation:
Goyal, A., Quader, R., Gibbon, L., Ulven, C. and Narayanan, L., "Flax Fiber-Based Packaging for E-commerce Applications", Fifth International Symposium on Materials from Renewables (ISMR 2025), July 1516 2025, North Dakota State University, Fargo, ND, USA.
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