Revista de Ciencias Tecnológicas (RECIT). Volumen 3 (1): 10-22
Revista de Ciencias Tecnológicas (RECIT). Universidad Autónoma de Baja California ISSN 2594-192
Volumen 4 (4): 287-298. Octubre-Diciembre, 2021 https://doi.org/10.37636/recit.v44287298.
ISSN 2594-192
287
Evaluation of particle board production from cotton gin
waste and urea-formaldehyde resin
Evaluación de la producción de tableros de partículas a partir de
residuos de desmotadora de algodón y resina de urea-formaldehído
Agustina Trevisan 1, Luciano Gabriel Massons 1, Florencia Benítez 1, María Fernanda Carrasco 1, Rubén
Marcos Grether 1, Ariel Anselmo González 2
1Universidad Tecnológica Nacional, Facultad Regional Santa Fe, Centro de Investigación y Desarrollo para la Construcción y
la Vivienda (CECOVI), Lavaisse 610, S3004EWB, Santa Fe, Argentina
2Universidad Tecnológica Nacional, Facultad Regional Santa Fe, Departamento de Ingeniería Civil, Lavaisse 610,
S3004EWB, Santa Fe, Argentina
Corresponding author: Luciano Gabriel Massons, Universidad Tecnológica Nacional, Facultad Regional Santa Fe, Centro
de Investigación y Desarrollo para la Construcción y la Vivienda (CECOVI), Lavaisse 610, S3004EWB, Santa Fe, Argentina.
E-mail: lmassons@frsf.utn.edu.ar. ORCID: 0000-0002-5584-5903.
Recibido: 18 de Julio del 2021 Aceptado: 11 de Octubre del 2021 Publicado: 20 de Octubre del 2021
Abstract. - The objective of this study is the evaluation of the feasibility of producing particleboard for
general use using cotton gin waste generated in Argentina and urea formaldehyde resin. The chemical
composition and size distribution of particles of the ginning residue as well as mechanical and physical
properties of the particleboards obtained were investigated. The Density and flexural strength of
particleboards produced by varying levels of urea-formaldehyde resin between 8.3 and 19.3% (solid to
solid ratio) were evaluated. The effect of incorporating jute reinforcement on the mechanical properties
of these boards was also analyzed. Particleboards with densities between 530 and 700 kg/m3 and variable
flexural strength between 0.30 and 5.85 MPa were obtained, allowing the minimum levels required for
low-density boards to be reached. Strength values achieved allow this particleboard to be used in
applications without structural requirements, such as door core or insulation.
Keywords: Cotton gin residue; Urea-formaldehyde resin; Particleboards; Jute.
Resumen. - El objetivo de este estudio es la evaluación de la factibilidad de producir tableros de
partículas para uso general utilizando residuos de desmotadora de algodón generados en Argentina y
resina de urea formaldehído. Se investigó la composición química y distribución de tamaño de las
partículas del residuo del desmotado, así como las propiedades mecánicas y físicas de los tableros de
partículas obtenidos. Se evaluó la densidad y la resistencia a la flexión de los tableros de partículas
producidos por niveles variables de resina de urea-formaldehído entre el 8,3 y el 19,3% (proporción de
sólido a sólido). También se analizó el efecto de incorporar refuerzo de yute sobre las propiedades
mecánicas de estos tableros. Se obtuvieron tableros de partículas con densidades entre 530 y 700 kg / m3
y resistencia a la flexión variable entre 0,30 y 5,85 MPa, lo que permitió alcanzar los niveles mínimos
requeridos para los tableros de baja densidad. Los valores de resistencia alcanzados permiten que este
tablero de partículas se utilice en aplicaciones sin requisitos estructurales, como el núcleo de la puerta o
el aislamiento.
Palabras clave: Residuos de desmotadora de algodón; Resina de urea-formaldehído; Tableros de
partículas; Yute.
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1. Introduction
Cotton production in the north of Santa Fe
province, is an important productive activity, as
in Chaco, Formosa, Santiago del Estero and
Corrientes, showing high geographical
concentration. This productive activity presents
some troubles that should be addressed.
In previous harvests, about 1,000,000 tons of
bulk cotton were obtained, leaving behind more
than 300,000 tons (approximately 1,195,000
cubic meters) of cotton gin waste (> 30 %),
consisting of fibril, carpels, and other
components, without any intended destination
[1].
In recent decades the use of mechanical
harvesting has become widespread, notably
improving the profitability of the crop, but
producing a greater amount of ginning residue
that must be disposed of effectively, generating
drawbacks and extraordinary costs to the ginning
sector [2].
This waste, which is usually stockpiled in the
open air, result in an exceptional habitat for
vermin and rodents and, likewise, they are self-
igniting, thus representing a danger to nearby
communities.
Another characteristic of the ginning sector that
is important to bear in mind is that it carries out
intensive activities for approximately 100 days a
year, in correspondence with harvest-ginning
campaigns, and then dedicates itself to
maintenance activities or other related activities
(processing of seeds) with minimal staff
requirements. This situation results in a reduction
of personnel or a reduction in working hours (and
therefore remuneration) of the local population.
One aspect of cotton production that threatens the
implementation of complex technologies in order
to reuse ginning waste is the variability of the
interannual production, registering in the last
decades campaigns that oscillate between
386,676 and 1,032,545 t of raw cotton, according
to data from the Ministry of Agroindustry and
CCIA [2].
Currently attempts are being made to use ginning
residues as livestock feed, although it is very
limited because of the low digestibility of the
material, which barely exceeds 20 %, a very low
value compared to other feed options [3-4].
Another use is composting, which appears to be
the most viable solution, although cotton gin
waste diffusion as a material to make compost is
somewhat limited and of low profitability [5-6].
Unfortunately, in most cases these ginning
residues are burned. Because most of the ginning
plants are located within the urban zones, they
originate serious pollution problems, with any
solution proposals, and which cause discomfort
among the residents of the surrounding
neighborhoods, who fear suffering some kind of
illness or respiratory affection. Hence, risks
associated with the burning of residues that may
be contaminated with toxic agrochemicals must
be considered [7-10].
Finally, although other possible uses such as
hydrolysis or pyrolysis are identified, the high
added value of the obtainable products is offset
by the excessive cost of installations and
operation, and the requirement for qualified
labor.
In this scenario, the possibility of developing
innovative construction elements with cotton gin
waste could help in addressing both
environmental and social problems in this agro-
industrial sector, as well as offering new
materials for application in building or simple
furniture manufacturing. In this direction,
possible applications are envisioned in order to
improve the habitability conditions of homes,
since in the northern region of Santa Fe province,
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there is a high percentage of constructions with
serious problems in their vertical and horizontal
enclosures [11].
The production of panels based on
lignocellulosic residues constitutes a dry
construction technology with thermoacoustic
insulating characteristics and good resistance to
degradation. Numerous studies have been
detected that propose the recovery of waste and
its application in particleboards, some of them
proposing these technologies as substitutes for
wood particleboards [12-24]. Some research
carried out in our country arouses special interest,
aimed at the production of panels based on corn
marl [12], used as lightweight, insulating and
easy-to-install ceiling plates. This type of
element could become a mechanical barrier in
order to prevent the attack by the kissing bug and
thus reduce the appearance of Chagas disease.
Dr. Mariana Gatani has carried out research work
in which peanut shells are used for the
development of particleboards intended for the
construction of enclosures and ceilings and
furniture [14-16].
In the present paper, some research advances are
presented on characteristics of the cotton gin
waste, its conditioning, the possibility of
obtaining particleboards, the properties achieved,
and the future perspectives identified in this
investigation.
2. Materials and methods
Cotton gin waste used for the particleboards
elaboration was obtained from stockpiles of a
ginning plant located in Santa Fe province
(Argentina). This residue is composed of cotton
fiber that cannot be separated in the industrial
process, carpels, branches of different sizes,
leaves, and dust that is incorporated during
collection (Fig. 3).
These residues were chipped in a hammermill
(LOYTO N ° 2), equipped with a 16 mm sieve
and 8 floating steel hammers. The granulometric
characterization of the ground and unmilled
ginning residue was carried out, after manual
homogenization of the samples and reduction of
their size by quartering. Sieves employed were:
½” (12.5 mm), 3/8” (9.5 mm), 4
(4.75mm), 8 (2.36 mm), 16 (1.18 mm) and
30 (0.6 mm), determining the weight of the
material retained in each one of them.
pH determinations [25], solubility in 1% NaOH
(TAPPI 212 om-02), solubility in cold and hot
water (TAPPI 207 om-93) were performed on
cotton gin waste. Results of solubility in hot and
cold water were corrected according to the ash
content. The average of two measurements was
reported.
After milling process, all the chips were dried, at
oven at 105 ± 2 °C, to 3 % moisture content from
a natural moisture level of 16 %.
Subsequently, the ginning residue was manually
mixed with the urea formaldehyde resin, with a
minimum solid content of 65 %, density of 1.26
g/cm3, gelation time at 100 ºC of 6 min and
viscosity at 25 ºC of 950 cps. Water was added to
the resin to achieve solid content of 55 % and a 5
% saturated ammonium sulphate solution was
used as a catalyst.
Resin content used for particleboard
manufacturing, varied from 8.3 % to 19.3 %
(based on oven dry weight of the particles).
After mixture homogenization, it was placed in a
mold, pressed until reaching a maximum
pressure of 4.75 MPa and then maintained at 70
°C for 30 minutes, obtaining boards with nominal
dimensions of 170 x 170 x 10 mm (Figure 1).
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Figure 1. Molding scheme
The use of bidirectional jute fabric with a surface
density of 252 g/m2 was evaluated as a
reinforcement (Figure 2). It was impregnated
with the same proportion of resin as the ginning
residue [20].
On particleboards obtained, determinations of
density, bending strength and modulus of
elasticity were made.
Density was determined according to IRAM
9705 procedure.
Bending strength was carried out according to the
guidelines of IRAM 9706, maintaining a
specimen length of 160 mm. Molded samples
were cut into 4 specimens of nominal dimensions
160 x 40 x 10 mm. These specimens were
conditioned for 48 to 72 hours prior to the test, in
a controlled environment at 20 ± 2 °C and 65 ± 5
% relative humidity. The load was applied in the
center of the span (140 mm), at a constant
deformation rate of 12 mm/min, until the failure
of the specimen was verified.
Figure 2. Bidirectional jute fabric
3. Results and discussion
Natural cotton gin waste has concave shapes,
which makes impossible to achieve an adequate
adhesion between particles. For this reason, it
was decided to grind this material, achieving
greater uniformity in particle size and improving
its morphological characteristics.
Table 1 shows the amount of residue particles
retained on each sieve, both for the residue in its
natural condition and for the chipped material. It
is noted that the fraction greater than 4.75 mm is
drastically reduced by grinding, corresponding to
95.85 % for the natural residue, while in the
chipped material it reaches 54.8 %.
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For chipped residue the amount of particles
smaller than 600 µm is 8.86 %, and it is
constituted by very fine remains of particles and
dust, which must be discarded in order to
manufacture particleboards due to its great
adhesive demand.
Table 1. Particle size distribution in cotton gin waste
Sieve
Individual retained
(%)
No.
Sieve
size
(mm)
Natural
waste
1/2
12.50
- - - -
3/8”
9.50
- - - -
4
4.75
95.85
8
2.36
- - - -
16
1.18
1.93
30
0.60
- - - -
100
0.15
1.04
Bottom
1.18
It can be appreciated a diversity of particle sizes
between 12.6 and 0.6 mm in the ground material,
since there are significant percentages retained in
each sieve. Consequently, length to thickness
ratio varies from 3 to 18. From the photographs
of each fraction retained on sieves (Figure 3),
different particle morphologies can be observed,
the most irregular ones corresponding to the
larger sizes and the flatter ones to the smaller
sizes. Brumbaugh [31] studied the effect of wood
flake size and indicated MOR values increased as
the length to thickness ratio increased to 250 and
remained constant at higher ratios, significantly
different from cotton gin particles used in this
investigation.
The results of solubility in 1% NaOH, in cold and
hot water of the residue are shown in table 2. pH
of the residue resulted equals to 5 for cold water
determination and 6,4 for hot water
determination. Cold water procedure constitutes
a measure of components such as tannins, gums,
sugars and coloring materials. Hot water
procedure also measures the starch, while the
NaOH extractions show the presence of low
molecular weight carbohydrates, mainly
hemicelluloses present in the sample.
Figure 3. Morphology of chipped cotton gin waste
retained in sieves: a) retained over ½”; b) passing ½”,
ret. 3/8”; c) passing 3/8”, ret. 4.75 mm; d) passing 4.75
mm, ret. 2.36 mm; e) passing 2.36 mm, ret. 1.18mm; f)
passing 1.18 mm, ret. 0.6 mm.
The comparison of the soluble components
presents in the ginning residue, with respect to
other materials such as hard and soft woods,
cereal stubble, and shells from other crops, such
as peanut and hazelnut shells, indicates values
higher than most of the species used in other
investigations, with the sole exception of
hazelnut shells [27-29]. In previous works [32] it
was found that by soaking ginning residue under
ambient conditions for 48 hours, it was possible
to reduce soluble components content at the same
time that residue wettability was improved. This
improvement cotton carpels also verified by
HakkiAlma et al. [30] as boards made with cotton
carpels soaked for 2 weeks under ambient
conditions showed less thickness swelling and
higher levels of bending strength. These changes
in the wettability of the residue could explain the
poor adhesion between the urea formaldehyde
resin and the residue in its natural state. At the
same time, inequity of pH of residue and resin
can hinder good bonding between them and
hardening of resin [34-35]. Level of pH of cotton
gin waste is 5 to 6.4, and the resin presents a pH
value of 8, resulting relatively different.
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Table 2. Cotton gin waste chemical analysis.
Chemical component
Percent
1 % NaOH solubility
46.0
Hot water solubility
16.1
Cold water solubility
11.9
pH in cold water
5.0
pH in hot water
6.4
Table 3 shows the average values of density,
bending strength (MOR) and modulus of
elasticity (MOE) obtained for the particleboards
made of cotton gin waste. Samples produced
without reinforcement are called N and those
with incorporation of bidirectional jute sheet on
each face are identified as N + Y. Bidirectional
jute sheets bonded to the particleboard covered
the total surface of each of the 170 x 170 mm
faces (Figure 4).
Table 3. Physical and mechanical properties of cotton gin
waste particleboards.
Sample
Pressure
(MPa)
Adhesive
(%)
Density
(kg/m3)
MOR
(MPa)
MOE
(MPa)
V-N
4.75
8.3
530
0.30
15
V-
N+Y
4.75
8.3
600
1.04
62
U-N
4.75
11.9
610
1.62
138
U-
N+Y
4.75
11.9
600
3.06
160
R-N
4.75
15.1
630
3.15
269
R-
N+Y
4.75
15.1
700
5.53
358
S-N
4.75
19.3
630
3.05
324
S-
N+Y
4.75
19.3
670
5.85
390
Particleboard density varies between 0.53 g/cm3
to 0.63 g/cm3 for those that do not incorporate
reinforcement (N) and between 0.60 g/cm3 to
0.70 g/ cm3 for the N + Y samples. In figure 5 it
can be seen that as the resin content increases,
there is an increase in density. This behavior is
similar for all particleboards, regardless of the
presence of reinforcement (Fig. 5) up to a content
of 15.1 %.
Density values obtained place unreinforced
particleboards in the low density (LD)
classification according to the ANSI A208.1
standard [33], which establishes an upper limit of
640 kg/m3. At the same time, the incorporation of
bidirectional jute reinforcement increases the
density values, reaching, for the highest
percentage of resin, the classification of medium
density (M) according to ANSI A208.1 (640 to
800 kg/m3) [33].
Commercial particleboards available in the area
present density values between 610 and 690
kg/m3, which are similar to those corresponding
to the experimental boards obtained. For these
commercial boards bending strength is between
8.5 to 19 MPa, modulus of elasticity between
1200 to 2300 MPa and the adhesive consumption
generally varies from 2.5 to 10 % of the weight
of the board. As can be appreciated resin content
levels are much lower than that required when
using cotton gin residue [28,36].
Figure 4. Panels obtained in the mouldings: (a) without
incorporation of reinforcement; (b) with incorporation of
bi-directional jute sheeting
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Figure 5. Particleboard’s density
Results of bending strength (MOR) of
particleboards produced (Table 3) indicate that
the increase in the resin content allows increasing
bending strength values, both in the case of plane
panels as well as for panels with jute
reinforcement. ANSI A208.1 [33] establishes a
minimum bending strength value of 3 N/mm2 for
LD-1 panels and 5 N/mm2 for those classified as
LD-2. In the case of medium density panels (M),
the required bending strength value corresponds
to 11 N/mm2. According to this standard, the
panels classified as low density (LD-1 and LD-2)
are reserved for their application doors insides,
while those classified as medium density (M) can
be used in commercial, industrial and
construction applications. It can be seen that, in
the case of samples without reinforcement, it is
only possible to reach the minimum value of
bending strength for resin contents of 19.3 %.
The particleboards that incorporate
reinforcement reach a minimum of 3 N/mm2 and
5 N/mm2, for resin contents of 11.9 % and 15.1
%, respectively.
Results obtained indicate that the increase in the
density of the material and the resin content have
a positive effect on the development of strength
(Figure 6) as well as on the stiffness, evidenced
by the increase in the modulus of elasticity
(MOE) (Figure 7).
In Figure 8 it can be observed that as the resin
content increases, the strength difference
between samples with and without jute
reinforcement increases. It can be explained
given that the adhesion between jute and cotton
gin waste also increases. When adding jute
fabric, although the density does not change
significantly, bending strength of particleboards
increases, since the jute acts as a mechanical
reinforcement, about 3 MPa for 19.3 % of resin,
allowing boards to achieve values established by
the ANSI A208.1 standard [33]. This effect is not
very significant for lower resin contents, since up
to 11.90 % resin content it is appreciated that this
reinforcement tends to detach from the panel
when the failure approaches (Figure 9a). On the
contrary, for resin contents of 15.1 and 19.3 %
the jute remains adhered and the breakage of its
fibers is observed, showing an effective
collaboration that improves mechanical
behavior.
Figure 6. Particleboards bending strength
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Figure 7. Particleboard’s modulus of elasticity
Figure 8. Differential increment in bending strength
due to reinforcement incorporation
a)
b)
c)
Figure 9. Particleboards with jute reinforcementfailure:
a) samples U (N+Y); b) samples R (N+Y); c) samples S
(N+Y).
Although no other investigations using complete
ginning residue have been detected, it has been
possible to identify works from other authors
working with stalks of cotton plants and carpels,
respectively [17, 26-27, 29, 31]. Güller used
stalks from cotton plants to make particleboards
with urea formaldehyde resin contents of 8 % for
the central layer and 10 % for the outer layers.
For these particleboards, he obtained densities of
600 and 800 kg/m3 and bending strength of 11.4
and 15.67 MPa, respectively [17].
This author obtained, for particleboards from
cotton stalks and urea formaldehyde resin,
variable strength values depending on the resin
content of the internal (ML) and external (OL)
layers and the final density of 4.38 MPa (density
400 kg/m3 10 % ML 12 % OL), 8.79 MPa
(density 500 kg/m3 10 % ML 12 % OL),
12.36 MPa (density 600 kg/m3 10 % ML 12
% OL) and 16.79 MPa (density 700 kg/m3 10
% ML 12 % OL) [16]. HakkiAlma et al. made
particleboards with cotton carpels with urea
formaldehyde resin contents of 9 % for the
central layer and 11 % for the outer layers. For
these boards, he obtained densities of 668 to 693
kg/m3 and bending strength of approximately
10.5 (unsoaked chips) and 11.5 MPa (chips
soaked for 2 weeks) [30].
Results of modulus of elasticity (MOE) are much
lower than those achieved by Güller [17], which
reached 2004 and 2705 MPa for panels with urea
formaldehyde resin contents of 8 % for the
central layer and 10 % for the outer layers.
Pirayesh et al [21] obtained for walnut shell
agglomerates and 9 to 11 % urea formaldehyde
resin content, bending strength values of 6.63
MPa and MOE of 1208.9 MPa.
It is evident that strength level obtained for the
particleboards made with the complete ginning
residue is affected by its heterogeneity and the
presence of particles of different shapes and sizes
such as carpels, branches of various sizes and
leaves, since the development of adherence
between these components is very complex.
Thus, it is also diminished by the presence of
cotton fibers, which, due to their high surface
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area and knotting, complicates a complete and
uniform impregnation with resin, generating
poorly bonded resin-fiber cores where the
strength decreases considerably.
4. Conclusions
From the results obtained in the research, it can
be concluded that:
It is possible to produce particleboards
from cotton gin waste and urea-formaldehyde
resin with properties close to those of low-
density commercial boards, complying with the
minimum requirements demanded by the
standards. Incorporation of jute reinforcements
significantly increases bending strength of
particleboards, reaching levels required for low
density boards by the ANSI 208.1 standard,
without incorporating complex steps in the
productive process.
Finding this type of new application area
for cotton gin residue can lead to decreasing
pressure on the forests, alleviation of raw
material shortage of wood industry in developing
countries and provide a second income for this
crop along with environmental benefits.
The characteristics of the residue cause
important demands for resin to achieve
acceptable physical and mechanical behavior of
the particleboards, which translates into higher
production costs. Simultaneously, high contents
of urea-formaldehyde resin are related to
considerable formaldehyde emissions that could
be harmful to health.
From the above arises the need to evaluate
alternative of replacement of urea-formaldehyde
resin for another one with greater compatibility
with cotton gin waste in order to increase strength
levels, or the incorporation of formaldehyde
sequestering additives to reduce emission levels
of this compound.
5. Acknowledgements
The completion of this work was possible thanks
to the collaboration of the cotton gininig plant
ACRIBA S.A. in Villa Minetti (Santa Fe
Argentina), funding from “Secretaría de Ciencia
y Tecnología” from Universidad Tecnológica
Nacional (Argentina) and collaboration of
Instituto de Tecnología Celulósica (FIQ-UNL
Santa Fe Argentina).
6.- Authorship and Contribution
Agustina Trevisan: Methodology; validation;
formal analysis; research; data curation; writing
original draft; writing: revision and editing;
visualization. Luciano Gabriel Massons:
Methodology; validation; research; data
curation; writing original draft; writing: revision
and editing; visualization. Florencia Benítez:
Validation; research; data curation; writing
original draft; writing: revision and editing;
visualization. María Fernanda Carrasco:
Methodology; validation; formal analysis;
resources; writing original draft; writing:
revision and editing; visualization; supervision;
project administration, acquisition of funds.
Rubén Marcos Grether: validation; data
curation; visualization; supervision. Ariel
Anselmo González: Validation; data curation;
writing original draft; writing: revision and
editing.
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