Manufacturing processes for strong hydrophobic bio-materials with hot pressing technology

Purpose and goal

The project aims to develop and improve properties of bio-based 3D honey-comb materials made of fluting, innerliner and liner. The constituent components are post-processed with high heat and high nip pressure to manufactured strong, water-resistant board without the use of plastic coating. In our project, the end user is a manufacturer in the flooring industry, who wants to replace EPS with more environmentally friendly materials. The goal is to test the new manufacturing processes in a real industrial environment where the products´ performance can be evaluated.

Expected effects and result

The new manufacturing process for 3D materials based on the hot pressing technology is expected to provide very strong and water resistant honey-comb products that can replace EPS and plastic coatings. Low use of chemical additives further contributes to reduced environmental impact. The expectation is that the manufactured hydrophobic materials can be joined technically with maintained mechanical properties. A production of light building materials from renewable materials with the requirements for both indoor and outdoor use will satisfy the market and consumers.

Planned approach and implementation

The approach is based on the hot-pressing technology, that utilizes the excellent binding capacity of lignin at high temperatures. The project will be carried out according to an ascending TRL ladder from laboratory trials to pilot trials and finally full-scale trials. At Miun, material testing is performed, whereafter tests are made on a steel belt press machine at MoRe. Based on these results, trials will be carried out at Ipco´s full-scale pilot plant. After conversion to honeycomb boards, the final tests are made at Flooré in the production of underfloor heating.