Project's information
| Project's title | Study on the fabrication of bioplastic composite materials based on banana fiber/polyester resin |
| Project’s code | TĐNSH0.02/22-24 |
| Research hosting institution | Institute of Chemistry |
| Project leader’s name | PhD. Dao Hai Yen |
| Project duration | 01/01/2022 - 30/06/2026 |
| Project’s budget | Approved budget: VND 8,000 million; Approved budget after a 5% reduction: VND 7,915 million; Of which, 100% is funded from the science and technology career budget (SNKH) |
| Classify | Grade A |
| Goal and objectives of the project | + To develop a technological process for manufacturing bioplastic composite materials based on banana fiber/PLA and PHA resins (PLA and PHA are products of Components 6 and 7 and from commercial sources). To fabricate bioplastic composite materials based on banana fiber/PLA and PHA resins. |
| Main results | Theoretical results: - The technological process for separating, recovering and modifying cellulose from banana pseudostem and leaf chips has been studied to meet the set requirements, specifically: + Separation conditions: Alkaline treatment in three steps: first alkaline treatment with 3% NaHCO3 at 105 °C for 60 minutes; second alkaline treatment with 3% NaOH at 120 °C for 30 minutes; bleaching with H2O2 at a concentration of 10 g/L at 50 °C for 40 minutes. + Modification conditions: Acetylation using acetic anhydride as the reagent, catalyzed by I₂ at 80 °C for 60 minutes. + Characteristics of the obtained cellulose fibers and powder: Fibrous product with fiber length 0.2–2 cm; cellulose content 95.03%; lignin content 1.08%; hemicellulose content 2.64%; ash content 1.25%; degree of substitution 1.54. - The fabrication of biocomposite materials based on a PLA matrix reinforced with modified cellulose fibers has been investigated to meet the set requirements, specifically: + Quantity: 30.9 kg of PLA-based biocomposite reinforced with cellulose fibers has been produced, of which 20 kg is used for drinking cup trials and 10.9 kg is stored as reference samples. + Product quality: Density 1.21 g/cm³; melt flow index MFI (190 °C/2.16 kg) 2.71 g/10 min; melting temperature 150.8 °C; glass transition temperature (Tg) 54.8 °C; tensile strength at break 48.1 MPa; elongation at break 4.8%; biodegradability 93.84% after 180 days of testing, compliant with TCVN 9493:2012. - The fabrication of biocomposite materials based on a PHA matrix reinforced with modified cellulose fibers has been investigated to meet the set requirements, specifically: + Quantity: 15.2 kg of PHA-based biocomposite reinforced with cellulose fibers has been produced. + Product quality: Density 1.22 g/cm³; melt flow index MFI (190 °C/2.16 kg) 15.2 g/10 min; melting temperature 174.6 °C; tensile strength at break 40.1 MPa; elongation at break 3.8%; biodegradability 92.22% after 180 days of testing, compliant with TCVN 9493:2012. - The application of PLA/BF material to manufacture drinking cups has been studied to meet the following requirements: + Quantity: 115 drinking cups have been produced, including 15 test samples and 100 retained samples. + Quality: Biodegradability: 93.61% after 180 days of testing; specific migration parameters: Pb 12.62 µg/kg, Cd 23.13 µg/kg, KMnO₄ 1.12 µg/L, total lactic acid 2.31 µg/L, dry residue 3.16 µg/L. These indicators comply with the requirements of QCVN 12-1:2011/BYT. - Three technological processes have been developed and approved by the host institution, including: + One technological process for pretreatment, separation and recovery of natural fibers from banana pseudostems with a capacity of 1 ton of fresh material per day. + One technological process for producing bioplastic composite material based on PLA reinforced with banana fibers, with a capacity of 10 kg/hour. + One technological process for producing bioplastic composite material based on PHA reinforced with banana fibers, with a capacity of 10 kg/hour. - Two internal standards for PLA/BF and PHA/BF material products have been developed and approved by the host institution. - Publications and training: The project has published 2 papers in international journals indexed in SCIE and 2 papers in domestic specialized journals. - Patent / Utility solution: 1 granted patent: Patent No. 41852, granted under Decision No. 127054/QĐ-SHTT dated 1 November 2024. - Training: The project has contributed to the training of 1 master’s student. |
| Novelty and actuality and scientific meaningfulness of the results | In the context of an increasing demand to replace conventional plastics with biodegradable materials, together with more stringent requirements on performance, safety, and quality standardization, this study contributes along a “full value-chain” approach: from biomass resources (banana pseudostem and leaf residues), to fiber-reinforced PLA/PHA-based composite materials and demonstrator products, all evaluated through standard test methods targeting applications in packaging and food-contact articles. * Scientific contributions + Establishing and optimizing a pre-treatment–separation–recovery sequence for cellulose fibers from banana pseudostems, thereby providing a scientific basis for converting agricultural by-products into a reinforcing phase with stable quality; at the same time, quantifying and characterizing fiber quality after treatment (purity, structure, morphology). + Clearly demonstrating the “improvement” in structural properties and thermal stability of the treated fibers, as evidenced by an increase in crystallinity index CrI from 47.6% to 62.5% and a rise in the onset decomposition temperature (Tonset) from 250 °C to 340 °C, thereby confirming the suitability of the fibers for melt processing with PLA/PHA. + Developing an evaluation protocol for biodegradation in accordance with TCVN 9493/ISO 14855 and TCVN 13114, determining and quantifying CO₂ mineralization under aerobic composting conditions (58 ± 2 °C; 180-day monitoring), thus generating a reliable dataset for PLA/BF and PHA/BF materials. The study also demonstrates suitability for packaging and food-contact applications via overall and specific migration testing in accordance with QCVN 12-1:2011/BYT (Pb, Cd, KMnO₄, total lactic acid, dry residue, etc.). + Translating material-level results into application-oriented research by designing formulations to study thermal stabilizers and crystallization behavior, and by evaluating product uniformity during injection molding of PLA/BF drinking cups. * Socio-economic contributions + Completing pilot-scale technological processes with clearly defined capacities, including: (i) recovery of fibers from banana pseudostem and leaf residues at a capacity of 1 ton of fresh biomass per day; (ii) production of PLA/BF bioplastic composite material at 10 kg/h; and (iii) production of PHA/BF bioplastic composite material at 10 kg/h. These outcomes lay the groundwork for technology transfer and product commercialization. + Developing two internal product standards for PLA/BF and PHA/BF materials, thereby standardizing quality, reducing risks during technology transfer, and supporting quality control activities in manufacturing. + Creating a practically implemented demonstrator product (PLA/BF drinking cups), which enhances market acceptance and supports the transition from conventional plastics to bioplastics in the single-use product segment. + Contributing to the added value of banana production by-products and to local livelihoods: utilizing readily available agricultural residues, reducing biomass wastage, and opening up opportunities to build integrated value chains for collection–preprocessing–materials–products in support of a circular bioeconomy in agriculture. * Environmental contributions + Reducing the pressure from persistent plastic waste. + Utilizing agricultural by-products in general, and banana pseudostem and leaf residues in particular, as feedstock, thereby reducing open burning and disposal of biomass and promoting a shift towards “resource recovery” of waste, supported by a standardized fiber separation–recovery process. + Enhancing environmental and consumer safety for food packaging applications: migration parameters in accordance with QCVN 12-1:2011/BYT meet the required limits, supporting the goal of replacing conventional plastics while still ensuring safe use. |
| Products of the project | - International research papers (SCI-E): |
| Images of project |  |
