Development of Waterproof Cum Heat Resistant, Montmorillonite Clay Modified High-Pressure Plywood Composite from Renewable-Nonedible Agricultural Wastes – An Industrial Case Study of ‘Flask to Reactor’ Approach

A sustainable development model demands an economical transition of product synthesis from ‘Flask to Reactor,’ which demands synchronization between universities, industries and funding agencies. In our lab, we have successfully developed a prototype method for synthesizing adhesive phenol-furfural resin from extracts of Saccharum munja while biomass residues of this feedstock extraction were employed as filling materials for manufacturing plywood samples. This designed method has the advantage of no leftover waste material. Moreover, waterproofing, heat resistance and mechanical strength were improved by impregnating functionalized montmorillonite clay into these prepared plywood samples. Subsequently, water and fire-resistant wood composite (MDF) was developed from agricultural residue on a pilot plant scale (Saccharum munja). Green precursor furfural (for resin/glue synthesis) was extracted from agricultural residue (Saccharum munja and peanut plant) on a pilot plant scale. Organic functionalization clay was also synthesized and incorporated during resin (Phenol-Furfural) preparation. Plant materials left after furfural extraction were further used for wood composite (MDF) preparation by hot pressing of plant residue and resin. Characterization and evaluation of prototype wood composite products were also performed for fire and waterproof analysis. Results have shown that prepared samples have good fire and water-resistant activities. This product will be a good candidate for the wood composite market and is green. Furfural, used for resin synthesis, is a potential replacement for carcinogenic formaldehyde, which is largely used in wood composite and plywood industries. Pakistan is an agricultural country and is enriched with mineral reservoirs. Fortunately, raw materials required for this project, i.e. renewable biomass including agricultural residue and nonedible plants, and minerals, i.e. montmorillonite clay, are available in ample quantities. Thus, this project has good potential to develop cost-effective and improved quality plywood products that are marketable and can generate positive cash flow. TTSF platform was employed to support promising partnerships between academia (HEC & NUST) and industry (KDC Boards (Pvt) Ltd, Woodworld (Pvt) Ltd & TASCO Mines (LLP)) to facilitate the transfer of university-developed technological research to industry and the commercial sector.