POTENTIAL OF CORN (ZEA MAYS) STOVER AND DAAT GRASS (CYPERACEAE)

AS AN ALTERNATIVE SOURCE OF FIBER IN PAPER PRODUCTION

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An Investigatory Project

Presented to the

Faculty of Engineering Department

Cebu Technological University

Sabang, Danao City, Cebu

__________________

In Partial Fulfillment

of the Requirements for

INDUSTRIAL MATERIALS AND PROCESSES (IE-PC 212)

__________________

By

Bracero, Dustine Joseph K.

Lavador, Nino Rey

Monte, Hasmen R.

Tariao, Romeo L. Jr.

 CHAPTER 1

INTRODUCTION

Environmental problem is one of the biggest issues throughout the world and

there is no accurate solution to ease the problem. This is mainly due to human

interventions and urbanization. The industrialization has caused negative effects to the

environment. The main concern aroused is the continuous cutting of trees or what we

know as deforestation to be used for industrial processes which affects the balance of

nature.

The wood usage is increasingly notable. A total of 3.8 billion 𝑚3 under bark of

wood was removed from global forests in 2016, of which around one half (50%) was for

use as woodfuel and the remainder was industrial roundwood (for use by wood

processors). Global production of wood products in 2016 totaled 467 million 𝑚3 of

sandwood, 415 million 𝑚3 wood-based panels and 409 tonnes of paper & paperboard.

This data shows wood consumptions which is becoming higher and higher every time.

The conflict arises as paper and paperboard plays an important role to the society.

According to figures for 2015, global paper consumption has reached 398 million tons per

year-which worked out to 12,620 kg per second in 2013. In 2015, global demand for paper

and cardboard increased by an average of 2.2%. Paper is used in different fields in the

community. In the office and school, packaging and even made as a substitute for plastic.

The impact of paper production to the society must be maintained but with reconsideration

of environmental problems. This concerns with the use of wood in paper production

process, owing to these environmental concerns and resources depletion, creating an

alternative way to minimize wood usage through other sources has recognized. Since

woods were already used, non-wood materials can be considered in the process.

The non-wood plants such as grasses and other types can be examined for

fiber extraction used for paper production. Its analysis and composition may be

comparable to that of the wood. The substitution of non-wood plants to wood can lessen

wood consumption on paper industry and to the overall wood consumption. This starts on

the local-based non-wood plants in the Philippines specifically corn (Zea Mays) Stover

and Daat Grass (Cyperaceae) as substitute for wood fiber in paper production. This study

focuses on the effectiveness of the stated non-wood plants alteration to wood in paper

production.

Review of Literated Literature

The demand for paper is steadily increasing because of continuous

industrialization and improvement of human education. This is the main reason why there

is also a continuous search for paper materials until today. Listed as possible sources are

vegetable fibers (wood, flax, cotton, and bagasses), mineral and nonmineral or synthetic

materials such as gypsum, asbestos, glass fibers, and synthetic fibers. The consumption

of paper, especially fine paper, continued to grow, increasing the demand for short fiber

pulp (Paavilainen 1996). In many countries wood is not available in sufficient quantities

to meet the rising demand for pulp and paper (Atchison 1987, Judt 1993).

Since the production needs fiber material in order to produce papers, other

materials containing fiber not mentioned in the listed source may be used in the process.
This includes the non-wood plants. Therefore, non-wood plant materials including, annual

plants and agriculture residues are potential substitute to replace the limited wood

resources in paper-based industries (Rodríquez et al. 2008 and Ververis et al. 2004).

In Egypt 3000 BC, pressed pith tissue of papyrus sedge (Cyperus papyrus L.) was

used as surfaces for writing dates and the earliest considered non-wood plants in paper

industry. Hence, the actual papermaking was discovered in AD 105 by Ts’ai Lun, where

fibers from hemp rags and mulberry (Morus alba L.) was found useful in papermaking. In

1827, the first commercial pulp mill began operations in the USA using straw (Atchison

and McGovern 1987). While Anselme Payen found a resistant fibrous material that is

present in most plant tissues. This was termed cellulose by the French Academy in 1839

(Hon 1994). In the 20th century, the main raw material for paper production is wood

through the invention of new chemical pulping methods.

The pulping method is used in paper production. All types of paper (Britannica,

1973) are made from pulp containing vegetable, mineral or manmade fibers that form a

matted or felted sheet on a screen when moisture is removed. Nearly all paper is made

cellulosic (vegetable) fibers (San Juan, 2011). In making paper pulp, plant fibers are not

the only substances needed. There are also additives that are blended together to

produce paper in desirable properties. These are resin, the sticky substance from plants,

alum for making the paper resistant to water, china clay which is responsible in achieving

smooth texture to paper while pigments and dyes are used for color and beautification. In

the final stages of papermaking an aqueous slurry of fiber components and additives is

deposited in a wire screen and water is removed by gravity, pressing, suction, and

evaporation (Biermann, 1993). A new fiber crop must fit the technical requirements for
processing into pulp of acceptable quality in high yield and must also be adoptable to

practical agricultural methods and economically produce high yield of usable dry matter

per acre (Nieschlag et al, 1960).

By the demand of paper throughout the world, many researchers have been

interested in finding new paper material. In northern Europe, focused on grasses and

other monocotyledons (Olsson 1993, Mela et al. 1994). In the study of grasses, canary

grass has been one of the most promising species for fine paper production in Finland

and Sweden (Berggren 1989, Paavilainen and Torgilsson 1994). Other grasses can also

be used in paper production such as tall fescue (Festuca arundinacea Schr.) (Janson et

al. 1996a, switchgrass (Panicum virgatum L.) (Radiotis et al. 1996) and cereal straw

(Atchison 1998, Lonnberg et al. 1996). There was also in central Europe which is elephant

grass (Miscanthus sinensis Anderss.) and is also used in energy production (Walsh

1997).

In order to produce a desirable quality of paper, fiber material must fit the technical

requirements. It must be adaptable to practical agricultural methods and produce

adequate dry matter (DM) and fiber yield at economically attractive levels (Nieschlag et

al. 1960, Atchison 1987b). In addition, a sufficient supply of good quality raw material for

running the process throughout the year (Atchison 1987b). Non-wood plants show high

biomass production capacity than wood species and higher pulp yields. Therefore,

continuous searching for non-wood plants for papermaking lead a significant role in the

society.
Conceptual Framework

INPUT
- Corn Stover - Daat Grass
- Bamboo Ash - Alum
- Resin - Water
- Dyes

PROCESS
- Pulping -Molding - Drying

OUTPUT
- PAPER

Figure 1.
THE PROBLEM

Main Problem:

Are Zea Mays Stover and Cyperaceae with Bambusoideae ash effective substitute

for wood in paper production?

Specific Problem:

1. Is Corn (Zea Mays) Stover effective for substituting wood in paper production?

2. Is Daat grass (Cyperaceae) effective for substituting wood in paper production?

3. Is Bamboo (Bambusoideae) ash effective in strengthening the paper?

4. What can be the best non-wood treatment for substituting wood in paper

production?

Statement of the Problem

This investigatory project, testing the possibility of Corn (Zea Mays) Stover and

Daat Grass (Cyperaceae) as an alternative source of fiber for paper production and

assessing its effectiveness as a substitute for wood in the papermaking. This is also to

test the usefulness of bamboo ash for making paper with desirable quality. Furthermore,

some questions may follow as:

1. Are fibers from Corn (Zea Mays) Stover and Daat Grass (Cyperaceae) can be a

substitute for wood fiber in making paper?

2. What can be the benefit in adding bamboo ash to the process of papermaking?

3. Which is the best alternative source of fiber among the samples?

a. Corn (Zea Mays) Stover

 b. Daat Grass (Cyperaceae)

c. Combination of Corn (Zea Mays) Stover and Daat Grass (Cyperaceae)

d. Corn (Zea Mays) Stover with Bamboo (Bambusoideae) ash

e. Daat Grass (Cyperceae) with Bamboo (Bambusoideae) ash

f. Combination of Corn (Zea Mays) Stover and Daat Grass (Cyperceae) with

Bamboo (Bambusoideae) Ash

Objectives of the Study

The main objective of this study is to test the effectiveness of corn (Zea Mays)

and Daat Grass (Cyperaceae) as an alternative source of fiber for paper production given

Bamboo ash as a strengthening additive. Specifically, this study aims to:

1. Test the effectiveness of Corn (Zea Mays) Stover for substituting wood in paper

production.

2. Test the effectiveness of Daat grass (Cyperaceae) for substituting wood in paper

production.

3. Test the effectiveness of the combination of Corn (Zea Mays) Stover and Daat

grass (Cyperaceae) for substituting wood in paper production.

4. Test the effectiveness of Bamboo (Bambusoideae) ash in strengthening the paper.

5. Compare the effectiveness of the two non-wood plants for substituting wood in

paper production.

6. Know the treatment that can be the best substitute for wood.
SIGNIFICANCE OF THE STUDY

This investigatory project tests the possibility of Corn (Zea Mays) Stover and Daat

grass (Cyperaceae) as an alternative source of fiber for paper production and assessing

its effectiveness as a substitute for wood in the papermaking. This is also to test the

usefulness of bamboo (Bambusoideae) ash for making paper with desirable quality. Thus,

if this would be found positive, the significance will be on the following:

 Community – The community can benefit from this study as it is notable that

most of the people uses paper in every task. From the students and teacher for

school uses, office workers for reports and files, small and big business

transactions, packaging and even at home.

 Farmers – This is significant to the farmers as they can make this as an

additional living means by sell the raw materials to different processors.

 Entrepreneurs – This study can benefit them in such a way that they can make

their own made paper or packaging which is cheaper and with raw materials

available in scope.

 DENR (Department of Environment and Natural Resources) – They can

benefit from this study because this can minimize wood consumption that can

lead to lesser percentage of tree cutting activities.

 Researchers – This can serve as basis for further study through the

recommendation for improvements and better results.

Flow of Research Process

THE PROBLEM AND ITS SCOPE

 Brainstorming
 Identifying the Problem
 Reviewing related literature
 Clarification of Problem

PROCESS AND DESIGN

 Experimental Research Design

 Product test by breaking strength test and moisture retention test
 Manipulating treatments depending on the result

OUTPUT/PRODUCT

 PAPER MADE FROM CORN STOVER AND DAAT GRASS

Figure 2.
METHODOLOGY

Choosing and
Gathering Mixing Molding

Cutting Screening
and Refining Designing

Boiling Rinsing Drying

Figure 3. Papermaking Process

Choosing and Gathering – The researchers will gather the raw materials and then

choose the ones which are suitable for the experiment. The two raw materials which are

the Corn (Zea Mays) Stover and Daat Grass (Cyperaceae) will be examined to have the

best choice of quality. In the Corn (Zea Mays) Stover, the stem, leaves and corn cobs will

be separated to determine the component/s which is/are good for the study. While in the

Daat Grass (Cyperaceae), only the leaves will be used.

Cutting – This includes the proper length of the raw materials to be prepared for boiling.

This also refers to the proper structure such as strips and box. In this experiment, the raw

materials will be cut as small strips, leaving the unnecessary parts of the grass.
Boiling – The raw materials will be boiled given different time limits to determine its

effects on making a good fiber for paper. The amount of water also will be controlled

depending on the amount of raw materials being boiled. This process is to soften the raw

materials so that the next process can be done.

Rinsing – This involves the cleaning and washing of the boiled raw materials to avoid

unnecessary particles which can affect the quality of the paper.

Screening and Refining – The raw materials that have been rinsed will then proceed to

the screening process to eliminate the excess water which is not needed for the

experiment. This also includes the refining of the screened raw materials to be ready for

mixing.

Mixing – In this process, the additives will be manipulated according to the desired

treatment and mix it to the refined raw materials. The additives include the alum, resin,

starch, water and the strengthening agent which is the bamboo ash.

Molding – This process is to make sure that the desired output will be seen. Through

molding, size, thickness and shape of the paper will be achievable and controlled.

Designing – This is the process where beautification happens by adding pigments and

dyes for colors more pleasing to the eyes.

Drying – This will be the last part or the finishing way to the formation of the paper. This

will determine the quality and the last process to assess the outcome of the experiment.
 Corn Daat Boiling Bamboo Alum Risen Starch Water

stover grass Time Ash

(g) (g) (hrs) (g) (g) (g) (g) (ml)

1000 1000 3-4 10-20 100 50 50-100 50-100

1000 1000 3-4 10-20 100 50 50-100 50-100

The product will be tested through breaking strength test where one member of

the group will hold the paper on each side. A string will be attached through the middle of

the paper. To the other end of the string, weights were added one by one until the paper

broke. The weight in which the sheet broke will be the breaking strength. To determine

the amount of water they each absorb, the moisture retention test will be performed. There

will be a certain amount of water which will be poured on each pre-weighed sample. After

a certain amount of time, the excess water will be shaken off and the sheets were again

weighed. By this test, the quality of the paper will be determined. ANOVA test will be used

for statistical analysis followed be the t test to determine the treatment having the best

quality of paper.

Scope and Limitation

This investigatory project assesses the effectiveness of non-wood plants as a

substitute for wood in papermaking. This mainly focuses on two kinds of non-wood plants

namely the Corn (Zea Mays) Stover and Daat (Cyperaceae) Grass. Furthermore, this will

also use another additive which is the bamboo ash as strengthening agent for the paper.

However, this study is only limited to determining fiber from the two non-wood plants and
pulp making process of paper. And thus, this only focuses on the assessment of the

effectiveness of those two non-wood raw materials through different treatments.

Research Design

This Investigatory project tests the possibility of Corn (Zea Mays) Stover and Daat
Grass (Cyperaceae) as an alternative source of fiber for paper production and assessing
its effectiveness as a substitute for wood in the papermaking which includes different
treatments to the raw materials. Therefore, this study uses a quantitative research design
as it emphasizes the objective measurements of the data in statistical, mathematical or
numerical way. The data needed for this study was collected through specific experiments
conducted by the researchers. The different treatments will be identified through the
dependent and independent variables which uses the experimental design.

Experimental research design is a type of quantitative design in which a controlled

experimental factor is subjected to special treatment for purposes of comparison with a
factor kept constant. This method used to establish the cause and effect relationship
between two variables or among a group of variables consisting the dependent and
independent ones. The researchers conducted these experiments to know the possibility
of using Corn (Zea Mays) and Daat Grass (Cyperaceae) as an alternative source of fiber
in paper production.

VARIABLES

 Independent variable/s – These variables are the raw materials which does
not change by the controlled variable which are the Corn (Zea Mays) Stover
and Daat Grass (Cyperaceae).
 Dependent variable/s – These variables changed depending on the
controlled variables. In this experiment, the paper quality is the dependent
variable.
 Controlled variable/s – These are the time and measurement.
 The researchers determine the comparison of the strength of Daat (Cyperaceae)

grass and Corn (Zea Mays) Stover in paper production given different treatments. This

applied the factorial experiment where there will be two factors being controlled. Hence,

using factorial experiment can lead to so many samples, the researchers will be doing

cluster random sampling. The non-wood fiber paper is an environment-friendly product

produced in a variety of colors. This study is intended to determine the effectiveness of

producing fiber paper from Corn (Zea Mays) Stover and Daat grass (Cyperaceae) to

come with a paper to reduce the need to cut down more trees for paper production.

Definition of Terms

1. Daat Grass (Cyperaceae)- This grass is commonly found in remoted areas

2. Fiber- It is extracted to Daat Grass (Cyperaceae) and Corn (Zea Mays) Stover

usually in string sizes

3. Corn (Zea Mays) Stover- are residue consisting stem, cobs and leaves.

4. Pulp- A pulverized component coming from the fiber

5. Bamboo (Bambusoideae) Ash- Made in a pulverized charcoal that is burned at a

temperature ranging 800-1200℃

6. Paper- The product made from the raw materials; Daat grass (Cyperaceae) and

Corn (Zea Mays) Stover

7. Alum- Is a component added in the mixture in making the paper.

8. Starch- A powdered substance added in the mixture.

9. Resin- A sticky substance from plants.