Production and Properties Chip Block Pallets from Teak Wood Waste

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Production and Properties Chip Block Pallets from Teak Wood Waste

In the current global trading era, logistics plays a pivotal role in efficiently distributing vast quantities of goods worldwide. Ensuring the safe transportation of commodities from suppliers to manufacturers, warehouses, retailers, and consumers is crucial. Within logistics systems, pallets are commonly used to safely and efficiently distribute large quantities of goods through various modes of transportation.

Traditionally, wood pallets have been relied upon as a dependable means of facilitating this process. However, the use of solid wood for block pallet production raises concerns regarding illegal logging and its detrimental environmental impacts. Addressing this issue in the wood industry requires exploring alternative materials and adopting sustainable practices aligned with ecological responsibility and adherence to legality.

Raw Material: Teak Wood Waste

Teak wood (Tectona grandis sp.) from the family Verbenaceae is a high-quality wood with a beautiful texture. The original distribution area of this species includes India, Laos, Myanmar, Indonesia, and Thailand, with plantations estimated to cover 4.346 million hectares. In Indonesia, particularly in Jepara and Central Java, teak wood has become a significant local commodity for the furniture industry, driving the wheels of local and national economies through furniture and handicraft exports to approximately 193 countries worldwide.

However, the wood production process also generates approximately 1.4 million cubic meters of wood waste annually, consisting of 22.32% wood slashes, 9.39% wood chips, and 8.77% sawdust. Traditionally, this waste has been used as compost to enhance soil fertility. Nevertheless, the economic value derived from this utilization remains relatively low and needs to be increased by exploring its potential in composite product applications.

Manufacturing Process

The use of waste wood products to produce chip block pallets (CBPs; pallet bearings) as functional composite products presents an opportunity for a sustainable pallet solution. The CBP production can be divided into two stages:

  1. Adhesive Content Evaluation: In the first stage, the polyurethane adhesive content was varied in four variants (2.5%, 3%, 3.5%, 4.5%), with a 50:50 particle size composition between coarse (4–14 mesh) and powdered (> 60 mesh) particles.

  2. Particle Size Composition: After determining the optimal adhesive content, the second stage evaluated the compositions of coarse (4–14 mesh) and powder (> 60 mesh) particles in five different ways.

The particles were mixed and sprayed with adhesive resins using a spray gun, then formed in a 9 × 9 × 9 cm3 molding box. The particles’ weight was adjusted to attain a density target of 0.6 g/cm3, and the mixture was pressed using the cold press method for 4 hours at a specific pressure of 9.8 MPa.

Pallet Specifications

The National Wooden Pallet and Container Association (NWPCA) standards were utilized to evaluate the physical and mechanical properties of the CBP products, including:

  • Density: The CBPs exhibited a density ranging from 0.57 to 0.61 g/cm3, meeting the intended target and close to those of commercial products.
  • Moisture Content: The moisture content of the CBPs was 6.84%, which is within the acceptable range.
  • Dimensional Stability: The lengths of the CBPs satisfied the required standards, but the height and width did not meet the prescribed standards after immersion.
  • Water Absorption: The water absorption values ranged from 80.80% to 84.91%, which did not meet the NWPCA criteria of a maximum of 25%.

Structural Integrity

The mechanical properties of the CBPs were assessed to determine their compressive strength (CS) and screw-holding strength (SHS):

  • Compressive Strength: The CS of the CBPs ranged from 11.18 to 14.67 MPa, satisfying the NWPCA standards, which require a minimum chip block strength value of 9.65 MPa.
  • Screw-Holding Strength: The SHS value increased with the addition of polyurethane adhesive, ranging from 104.68 to 371.50 N. The highest SHS value was achieved at an adhesive content of 4.5%.

These results demonstrate that the CBPs derived from teak wood waste closely resemble commercial chip blocks and have the potential to replace wood bearings as pallet pads.

Environmental Sustainability

Addressing the environmental concerns associated with traditional wood pallets, the utilization of teak wood waste for CBP production offers several advantages:

  1. Waste Reduction: The repurposing of teak wood waste, which would otherwise be discarded, contributes to a more sustainable waste management approach.
  2. Eco-Friendly Alternative: The use of polyurethane adhesives instead of formaldehyde-based synthetic adhesives eliminates the emission of harmful chemicals, promoting a more environmentally responsible production process.
  3. Economic Opportunities: The conversion of teak wood waste into value-added composite products, such as CBPs, can unlock new economic opportunities for the furniture industry and local communities.

Cost-Effectiveness

Compared to traditional wood pallets, the production of CBPs from teak wood waste can be a more cost-effective solution for logistics and packaging applications. The utilization of readily available industrial byproducts as the raw material, combined with the efficient manufacturing process, can lead to reduced production costs. Furthermore, the potential for multiple reuses of CBPs can contribute to long-term cost savings in logistics operations.

Applications of Chip Block Pallets

The versatility of CBPs derived from teak wood waste extends beyond their primary use in logistics and transportation. They can also find applications in the following areas:

Logistics and Transportation

CBPs can serve as an efficient and sustainable alternative to traditional wood pallets for the safe and reliable movement of goods through various modes of transportation, including trucks, ships, and trains.

Construction and Landscaping

The sturdy and moisture-resistant properties of CBPs make them suitable for use in construction and landscaping applications, such as temporary flooring, scaffolding, and outdoor furniture.

Furniture and Home Decor

The aesthetic appeal and durability of teak wood-based CBPs can be leveraged in the furniture and home decor industries, where they can be incorporated into unique and eco-friendly design solutions.

Conclusion

The production of chip block pallets from teak wood waste presents a promising solution to the environmental and sustainability challenges associated with traditional wood pallets. By leveraging the abundant teak wood waste generated by the furniture industry, the CBP manufacturing process offers a cost-effective and eco-friendly alternative that can meet the structural integrity requirements of the logistics and packaging sectors. The successful implementation of this innovative approach can contribute to waste reduction, promote environmental sustainability, and create new economic opportunities for local communities.

For more information on sustainable roofing solutions, visit Genuine Roof Systems.

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