Application of novel feeding system extrusion in manufacturing Tropical Kenaf Plastic Composite

Khalina Abdan, Phd

Laboratory of Biocomposite Technology,

Institute of Tropical Forestry and Forest Products,(INTROP)

Universiti Putra Malaysia,43400,Serdang, Selangor.

Presentation outline Overview of Kenaf Malaysia Kenaf Fibre Processing Extrusion Feeding System Kenaf Polymer Composites Potential of Biobased Composite Industry in

Malaysia

KENAF MECHANIZATION

4

Land PreparationSowing & Fertilising

1 week

3.5 Month old

Pest Control 2 months

2nd fertilizing

Overview of Kenaf Industry in Malaysia

The developing of kenaf industry is reflected by two important

events:The transformation of (MNTB) to Malaysian National Kenaf and Tobacco Board (MNKTB) and the inclusion of kenaf industry as one of strategic industries under the East Coast Economic Region (ECER) Development Program

Malaysian government has taken the initiative to focus on the development of kenaf-based products by integrating the upstream to downstream processing R&D, towards economic and marketing activities

Kenaf Fibre Processing

Infield Processing (decortication) (MNKTB)

Whole stem to long bast and water retting

Hammer mill processing (KFI Sdn. Bhd.) Whole stem to short bast and core fibre (10 -20mm),

Pulverizing process (Polyregion Sdn. Bhd.) Chip fibre to fine fibre (0.2-1mm)

ChipPulverise

Screening process

Fibre Density (g/cm3)

Elongation(%) Tensile Strength(MPa)

ElasticModulus (GPa)

Cotton 1.6 7 287 5.5

Flax 1.5 2.7 345 27.6

Hemp 1.5 1.6 690 70

Sisal 1.5 2 511 9.4

Ramie 1.5 1.2 400 61.4

Kenaf 1.4 1.6 930 53

Jute 1.3 1.5 393 26.5

Coir 1.2 30 175 4.0

Bledzki et al.,2000

FIBRE PROPERTIES

Graph L/D ratio

Graph bulk density

Graph moisture content

Bulk density for kenaf(250µ -650µ)

FIBER CHARACTERIZATION: FIBER CHARACTERIZATION: Physical Properties Properties

DTG kenaf fiberFT-IR Graph

Water degradatio

n

Water degradatio

n Lignin degradation

Lignin degradation

Hemicellulose degradation

Hemicellulose degradation

Hemicelluloses

O-H plane bending

(3341cm-1 and 3345

cm-1)_

FIBER CHARACTERIZATION: FIBER CHARACTERIZATION: Thermal and Thermal and Chemical PropertiesChemical Properties

Florescence Microscope

Kenaf fiber SEM photomicrograph illustrating the present of hollow portion in

natural fibre (1000x).

SEM photomicrograph illustrating the present of kenaf fiber in plastic

composite

FIBER CHARACTERIZATION: FIBER CHARACTERIZATION: MorphologicalMorphological

Extrusion Feeding System

It has been designed to provide less clogging and efficient mixing of kenaf and plastic in order to achieve desire fibre loading using various fibre mesh by applying continuous feeding system

The feeding rate study was conducted to identify relationship between fibre mesh and the highest potential fibre loading

The optimization processing condition was examine to determine the suitable feeder speed, main screw mixer speed and mixing temperature.

Plastic FeederKenaf Feeder

Twin Spiral ScrewAgitator

Water Bath

Biocomposite Twin Screw Extruder :

Main Part of Extruder : Feeder

Side Feeder motorMain Feeder

Motor

To ensure continuous feeding of kenaf ; two motors are required whereby first motor dedicated to avoid clogging and second motor devoted for transportation of kenaf fiber

Main Feeder Side feeder

Motor Single Unit 2 Units

Input Plastic resin Kenaf fiber

Advantages of Kenaf Feeder

1. High in output precision2. High volume of output

Project’s Potential

Feeder for light weight material in composite compounding and extrusion industries, food industries and material handling industries.

Motor Speed Output Tolerance

Double Stage Feeder 25 Hz 177 g/min ±3%

Single Stage Feeder 25 Hz 82 g/min ±11%

Compounding zone

Melting Zone

Kenaf enter the barrel

Metering Zone

Main Part of Extruder : Barrel

Zone 1 2 3 4 5 6 7 8 9 10

Temperature (oC) 190 200 220 220 190 190 190 190 190 190

15 CM

15 C

M

Dumble Size

Instron Tensile Test Machine

The research was supported by Grant of Economic Planning Unit, Prime Ministry Department

Title : Development of Biocomposite Material

from Kenaf Fibre for Industrial Building System and Furniture Component.

Sub research title: Rheological Behaviours of Kenaf Fiber Reinforced Plastics Composite prepared using Biocomposite Twin Screw Extruder.

NATURAL FIBRE REINFORCED PLASTIC COMPOSITE MILLS

Acknowledgement