Research Articles

Lean Manufacturing has helped several industries to achieve operational and manufacturing excellence by increasing productivity and enhancing quality, while reducing waste and costs. However, the wood industry has been historically slow in adopting this philosophy and its many tools. In times when overseas competition has taken big portions of the traditional market share for U.S based wood industries, it has become important that companies start to take actions in order to regain competitiveness. In this sense, Lean Manufacturing could provide a competitive advantage. Main findings of this project includes high percentages of Lean Manufacturing implementation among companies from the Wood Component Manufacturing Association, substantial differences in the tools implemented by companies on an early vs. extensive Lean Manufacturing implementation stage, as well as identification of main reasons and advantages derived from its implementation, and how Lean Manufacturing is rated among these companies. Findings lead to the conclusions that many companies are pursuing cost savings strategies without implementing Lean Manufacturing. Training and education on Lean Manufacturing, and well implemented Lean Manufacturing programs would help members of the Wood Component Manufacturing Association to regain competitiveness and achieve substantial cost reductions.

Cotton linters were hydrolyzed with different concentrations of HCl (2.5-15%) to prepare microcrystalline cellulose. Infrared spectroscopy and thermal analysis were used to follow the effect of hydrolysis on the molecular structure of the produced microcrystalline cellulose. The loss in weight and the degree of polymerization of the produced hydrolyzed cotton linters were determined. Scanning electron microscope images and x-ray diffraction were also studied for more information about the crystallinity, fiber length, particle size, and shape of the produced microcrystalline cellulose. Water retention value and water absorption were estimated for the hydrolyzed cotton linters to explain the effect of hydrolysis on the amorphous and crystalline part of the hydrolyzed cotton linters. The obtained results showed that the crystallinity index of the hydrolyzed cotton increased by increasing acid concentration and then began to decrease at 15% HCl. Kinetic energy (calculated from thermogravimetric curves) of the hydrolyzed cellulose was higher than that of the untreated cotton linters, and at high acid concentration this activation energy began to decrease.

Biotechnological processes represent a challenge in the control field, due to their high nonlinearity. In particular, continuous alcoholic fermentation from Zymomonas mobilis (Z.m) presents a significant challenge. This bioprocess has high ethanol performance, but it exhibits an oscillatory behavior in process variables due to the influence of inhibition dynamics (rate of ethanol concentration) over biomass, substrate, and product concentrations. In this work a new solution for control of biotechnological variables in the fermentation process is proposed, based on numerical methods and linear algebra. In addition, an improvement to a previously reported state estimator, based on particle filtering techniques, is used in the control loop. The feasibility estimator and its performance are demonstrated in the proposed control loop. This methodology makes it possible to develop a controller design through the use of dynamic analysis with a tested biomass estimator in Z.m and without the use of complex calculations.

The incorporation of crop residues was studied in particleboard panels (agrifibers, AG) in mixture with wood from Pinus radiata D. Don. Four crop residue stubble types were used, wheat, corn, rice plants, and rice husk. Their densities were compared. A wide array of mixtures varying from 9:1 = wood:AG to 1:9 = AG:wood were used to make the boards, from which the fundamental physical and mechanical properties were determined, to select one with the best properties and use potential. All AG were suited for board panels, although wheat and corn stubble gave better results, and their low fibre content was easily incorporated in low proportions without major modifications of processes and products.

Bamboo culm is a hygroscopic lignocellulosic material. Hygroscopic properties may be disadvantageous in bamboo material if applied in certain applications and modes where and when extreme moisture variations are likely to occur. This study was aimed at evaluating the moisture absorption and resistance including dimensional stability properties of neem seed oil-treated split bamboo samples using two methods of treatment. Split bamboo samples from the same source were oven-dried at 103±2oC, conditioned to 11.76% mean moisture content, and treated by completely soaking them in oil at room temperature for 24 hours and by soaking in hot oil at 60oC for 4 hours, with untreated samples as control. Results showed that samples soaked in hot oil at 60oC for 4 hours had both the least percentage water absorption and higher anti-swell efficiency, followed by samples soaked in oil at room temperature for 24 hours. Shrinkage in the longitudinal, radial, and tangential directions also followed the same trend. Conclusions and recommendations were made in line with the outcome of the study.

Conventional bleaching of hardwood CMP pulp with magnesium hydroxide (Mg(OH)2) show significant benefits over bleaching with sodium hydroxide (NaOH) under various conditions. Magnesium hydroxide bleaching generate higher optical properties, higher pulp yield and lower effluent COD at the same chemical charge, but the physical properties were found to be similar for both processes. The initial freeness of the bleached pulps and refining value to reach a target freeness (about 350 ml. CSF) were more for the Mg(OH)2-based process. The residual peroxide of filtrate from the Mg(OH)2-based process was very high as compared to conventional bleaching.

A strength grading process, starting with log grading, was studied with respect to grading yield, impact on quality, and economic efficiency when visual grades according to Nordic grading rules were used for alternate product comparison. Pine (Pinus sylvestris) and spruce (Picea abies) logs and boards were graded with several varieties of commercial grading and strength-grading equipment. The boards were destructively tested, and the European grade-determining properties strength, stiffness, and density were measured. Models for these were made by partial least squares and validated. A method for the derivation of settings for multiple indicating properties, which increased yield in some cases, was proposed and evaluated. Grading to grade combinations of C40, C30, and C18 was done. The impact of visual override based on deformations was also studied. A simplified economic and sensitivity analysis was done. The outcome was that log grading can be used for strength grading with good economic and quality results. Strength pregrading on logs improves sawmill economy, depending on the species and market situation. Drying quality greatly influences the yield through visual override grading on deformations. Market prices of high grades (>C30) must improve in order to stimulate supply, as it is more economical to produce lower grades.

Natural fibres are partly replacing currently used synthetic fibres as reinforcement for polymer composites. Jute fibre bundles were high-cellulose-content modified by alkali treatment, while the bagasse fibre bundles were modified by creating quinones in the lignin portions of fibre surfaces and reacting them with furfuryl alcohol (FA) to increase their adhesiveness. The effects of different fibre bundle loading and modification of bagasse fibre surfaces in hybrid fibre reinforced epoxy composites have been studied. The role of fibre/matrix interactions in chemically modified hybrid composites were investigated using Differential Scanning Calorimeter, Differential Thermo Gravimetry, and a Universal Tensile Machine and compared with those of unmodified bagasse fibre bundles incorporated with modified jute fibre bundles reinforced hybrid composites. Fibre surface modification reduced the hydrophilicity of fibre bundles, and significantly increased mechanical properties of hybrid composites were observed in conjunction with SEM images. The SEM analysis of the fibre and the composite fractured surfaces have confirmed the FA grafting and shown a better compatibility at the interface between chemically modified fibre bundles and epoxy resin. This paper incorporates interesting results of thermomechanical properties and evaluation of fibre/matrix interactions.

Solid nanocatalyst aluminum dodecatungstophosphate (Al0.9H0.3PW12O40, abbreviated as AlPW) with nanotube structure was synthesized through a natural cellulose fiber template. The AlPW nanotubes, which are highly water-tolerant and acid-tolerant, can be described as green double acids, as they combineand Lewis acid sites. They have been applied as an efficient nanoheterogeneous catalyst for the preparation of biodiesel from waste cooking oil containing 26.89 wt% high free fatty acids (FFAs) and 1% moisture via esterification of FFAs and transesterification of triglycerides in one pot under mild conditions.

Rice straw (Oryza sativa L.) pulp was treated by high intensity ultrasonication to make fibrils. The rice straw fibril (RSF) material was used as reinforcement in an RSF/polypropylene (PP) composite. The influences of RSF and coupling agent (MAPP) contents on tensile properties of the composite were tested. The results showed that when RSF loading was 5%, the tensile strength rose to a maximum value of 31.7 MPa. With increasing fibril loading the tensile modulus increased first, then decreased. However, the elongation at break decreased with increasing fibril loading. There was no significant influence of MAPP content on tensile strength and elongation at break of PP and RSF/PP composite. When MAPP content was 4%, the tensile modulus of PP and RSF/PP composite all showed maximum values.