Panel Perspectives: Emulco | 41


We are proud to contribute to a more sustainable wood and construction sector.”


EMULCO AND AQUAVEG RESEARCH Emulco specialises in high-end and complex emulsions such as EPDM, PIB and bio- emulsions for the wood, food packaging, construction, cosmetics, chemical and textile industries. Headquartered in Ghent, Emulco says it serves customers all over the world. The IPPS conference in Wales last October


saw a presentation on ‘Combining bio-based resins with bio-based wax emulsions to produce zero emission panels’, with Emulco’s Rob Van Hooghten sharing details of the research.


One of the main principles behind the research was that, although conventional paraffin wax emulsions are effective and available at a relatively low cost, they are by definition not sustainable. In the research, Emulco’s Aquaveg bio- based wax emulsions were based on partially hydrogenated vegetable oils – rapeseed, palm, coconut oils etc. The resins used from SESTEC - W508 (for PB production) and W67G (for MDF) covered by patent application – were based on natural renewable polymers – plant proteins. The attractiveness of this material is due to a variety of functional groups which after modification ensure a good wood bonding.


All PB and MDF samples were prepared in the SESTEC Polska Sp laboratory. The Aquaveg bioemulsions showed


characteristics of intrinsic water repelling properties, as well as a similar melting point and hardness as paraffin waxes. Furthermore, they are said to be non-toxic,


VOC-free and have a high melting point, implying that almost no evaporation of the wax occurs during pressing of the panels. In the testing, particle size distribution of the bio-wax emulsions is measured after several treatments: shelf-life testing, thermal cycling between room temperature and 50O


C


and accelerated aging in a centrifuge. Testing showed particle size distribution was not altered after the treatments. The distribution was monomodal with a mean of around 400-500mm. Four emulsion types were shown to be the most suited for PB and MDF production. The key difference between the emulsions is the wax blend and the surfactant type. When the biosurfactant was used to stabilise the emulsion, a biocontent and a biocarbon content of almost 100% was reached. The low viscosity of the emulsions in


combination with the low droplet size is expected to give a good spreading of the bio-wax on the chips and fibres. All test boards were produced at a target density of 650kg/m3 MDF.


for PB and 820kg/m3 The addition of a hydrophobing emulsion


to the PB significantly increased the resistance to water, with both the swelling and water absorption lower compared to an emulsion-free panel. For the conditions under study, one of


the Aquaveg emulsions reduces both by approximately 25% compared to reference fossil emulsion. This improvement is said to be so meaningful that researchers will expand their tests and activities. Mr van Hooghten shared how combining bio-based resins with bio-based wax


emulsions could produce zero emission panels.


MDF and PB samples produced with the natural products achieved results comparable to, or better than the reference paraffin wax emulsion panel. The panels met the IB and MOR standards for class P2 and MDF.


Because SESTEC resins and Emulco bioemulsions contain natural, environmentally-friendly ingredients, it makes them safe for both employees on the production line and consumers. Test panels were also assessed for formaldehyde emissions, with reported results being steady state values after five days in the testing chamber on a total testing period of 12 days. The results show the formaldehyde emissions of the bio panels were very low, even below the European and Japanese emission limits. The PB sample registered 0.008mg/m3


and the MDF 0.032mg/m3 for


compared to the Europe E1 standard (0.124mg/m3 (0.034mg/m3


) and Japan’s standard ). It is to be noted that the new


commission regulation (EU) 2023/1464 of July 14, 2023, sets a new maximum limit of 0.062mg/m3


.


The emission of the PB board tested is particularly low, considering no surface treatment (eg lamination) or formaldehyde scavenger is added.


This research and the start of


commercialisation of the Aquaveg emulsion will be interesting to watch as the field of environmentally-friendly low-carbon building and furniture products is currently of intense interest and scrutiny. ●


,


Above left: Emulco has a three-tier lab to pilot to production facility Above right: Emulco’s Rov Van Hooghten at IPPS in 2023


www.wbpionline.com | December 2023/January 2024 | WBPI


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