W.R.A.P.S

Waste Reduction through Agricultural Packaging Solutions

Abstract

A meaningful way to prevent waste is to create packaging from recycled waste materials, though most recycled packing materials still use around 50% virgin feedstocks to make the final product. Corn is the largest agricultural product in the United States and contributes to over 250 million tons of biowaste annually. To reduce the need for virgin feedstocks in single-use materials, lignocellulosic waste corn husks are a viable option to create environmentally-friendly, recyclable and compostable packaging. In this project, we will design and test a circular process with benign oxidants for making a paper-based packaging material derived from corn husks with a high percentage of waste-derived content (> 75% by mass).Our goal is to use circular processes to connect designers and consumers to help them think about the sustainability of everyday materials. This can help increase the percentage of recycled content in packaging materials and reduce the effects of waste from paper and plastics manufacturing.

Process

To make the new material, we first break down the cornhusks by cutting and blending. After, we begin to ozonate the husks. In this process, we pump ozone into a large container filled with cornhusks. The large container is connected in series to two flasks that contain Sodium Hydroxide (NaOH) and charcoal, respectively. The NaOH helps break down the cornhusks, and the charcoal breaks down to ozone for safety. After that, we blend the husks a second time and mix 4 parts corn husks to 1 part reclaimed material (paper, lint, banana). We then pull a sheet of paper using a deckle and mold.

Skills

Scanning Electron Microscope (SEM)
Infrared (IR) Spectroscopy
Paper Making
Life Cycle Assessment
Funding Acquisition
Procedure Development

Results

Paper Samples

SEM Images

IR Graph

The methods focused on using a mild ozonation to break down the cellulose-lignin bonds in waste cornhusks, making it suitable for use in various non-adhesive paper materials. The initiative expanded to include a diverse array of additional seasonal feedstocks including lint, banana peels, pina fibers, and sawdust allowing us to explore the compatibility of waste streams found across FIT and external sources. After making paper samples, chemical and materials analysis using infrared spectroscopy and scanning electron microscopy revealed the suitability of the feedstocks for making functional and decorative papers. Mechanical testing of the different papers helped us analyze the dry strength, density, and moisture management of our samples.

Published Manuscript

Relating Sustainability Metrics to Evaluate Circularity and Material Efficiency ↗
Austin Marshalek
Andie Zion
Julian R. Silverman

Exhibitions

2025 SUNY Undergraduate Research Conference
Binghamton, NY
Presented by Andie Zion

29th Annual Green Chemistry and Engineering Conference
Pittsburgh, PA
Presented by Austin Marshalek

Authors

Austin Marshalek
Andie Zion
Julian R. Silverman Ph. D

Thanks

FIT Sustainability Council
Huipu Gao, Ph. D
Sandra Krasovec

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Austin Marshalek

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