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ARS Home » Plains Area » Brookings, South Dakota » Integrated Cropping Systems Research » Research » Publications at this Location » Publication #216366
Title: DESIGN PROPERTIES FOR MOLDED, CORN-BASED DDGS-FILLED PHENOLIC RESIN COMPOSITES

Author
item TATARA, ROBERT - NORTHERN ILLINOIS UNIV
item Rosentrater, Kurt
item SURAPARAJU, SRIKRISHNA - NORTHERN ILLINOIS UNIV

Submitted to: Industrial Crops and Products
Publication Type: Peer Reviewed Journal
Publication Acceptance Date: 3/6/2008
Publication Date: 5/20/2008
Citation: Tatara, R., Rosentrater, K.A., Suraparaju, S. 2008. Design properties for molded, corn-based ddgs-filled phenolic resin composites. Industrial Crops and Products. DOI 10.1016/j.indcrop.2008.03.002.

Interpretive Summary: Because the fuel ethanol industry has grown rapidly in recent years, research must be devoted to maximizing the use of process residues. The primary coproduct is Distillers Dried Grains with Solubles (DDGS). Because this material contains high fiber levels, it may be appropriate for incorporation into bio-based composites. The goal of this study was to demonstrate the viability of using corn-based DDGS as a biofiller with phenolic resin, in order to produce a novel biomaterial. DDGS was mixed with phenolic resin at four levels (0, 25, 50, and 75%), and then compression molded using three pressures (13.8, 34.5, or 48.3 MPa [1.0, 2.5, or 3.5 tons/in²]) and three temperatures (157, 174, or 191 oC [315, 345, or 375 oF]). The performance of the molded specimens were then tested by measuring a variety of mechanical and physical properties. Pressure and temperature each had little effect on the resulting properties. DDGS level, on the other hand, greatly influenced all of the properties. As the DDGS content increased, Tensile yield strengths ranged from 29 MPa (4142 lb/in2) to 4 MPa (621 lb/in2), while the Young’s modulus ranged from 2634 MPa (381963 lb/in2) to 841 MPa (121920 lb/in2). For all time periods studied, water absorption increased as DDGS level increased. Moreover, as DDGS content increased, biodegradability increased from 0% to 38%. These results were similar to those from other studies that have investigated biofillers. Follow-up research should aim to optimize the strength of the DDGS composites through the use of coupling agents or other additives.

Technical Abstract: With the rapid growth in the fuel ethanol industry in recent years, considerable research is being devoted to maximizing the use of processing coproducts, such as Distillers Dried Grains with Solubles (DDGS), in livestock diets. Because these residues contain high fiber levels, they may be amendable to incorporation into bio-based composites as well, which is an option that could garner greater economic returns. Thus, the goal of this study was to demonstrate the viability of using corn-based DDGS as a biofiller with phenolic resin, in order to produce a novel biomaterial. DDGS was blended with phenolic resin at four levels (0, 25, 50, and 75%, by weight), and then compression molded using three pressures (13.8, 34.5, or 48.3 MPa [1.0, 2.5, or 3.5 tons/in²]) and three temperatures (157, 174, or 191 oC [315, 345, or 375 oF]). Molded specimens were then tested for a variety of mechanical and physical properties. Pressure and temperature each had little effect on the resulting properties. DDGS, on the other hand, greatly influenced all of the properties. Tensile yield strengths ranged from 29 MPa (4142 lb/in2) to 4 MPa (621 lb/in2), while the Young’s modulus ranged from 2634 MPa (381963 lb/in2) to 841 MPa (121920 lb/in2) as the DDGS content increased. For all time periods studied, water absorption increased as DDGS level increased. Moreover, as DDGS content increased, biodegradability increased from 0% to 38%. These results were similar to those from other studies that have investigated biofillers. Follow-up studies should aim to optimize the strength of the DDGS composites through the use of coupling agents or other additives.