Valorisation of Agricultural Residue Bio-Mass Date Palm Fibre in Dry-Blended Polycaprolactone (PCL) Bio-Composites for Sustainable Packaging Applications

Abstract Purpose This study experimentally developed and characterised dry-blended Polycaprolactone (PCL)/date palm fibre biodegradable composites for sustainable packaging applications. Date palm fibres are collected from date palm trees as by-products or waste materials. They will be valorised in bio-composite application to promote fibre-based sustainable packaging items over their non-biodegradable synthetic polymer based conventional packaging products. In the dry-blending process, fibre and polymer are mixed with a shear mixer, while, in a melt-blending process, an extruder is used to extrude fibre/polymer blends after applying heating and high shear pressure to melt and mix polymer with fibres. Dry-blending process offers many comparative advantages, such as less equipment, steps, cost, process degradation, energy consumption and hence, lower harmful environmental emissions; while, a proper fibre/polymer mixing is a challenge and it needs to be achieved properly in this process. Therefore, it is important to understand the effects of dry-blending process on manufacturing of PCL/date palm fibre bio-composites for packaging applications, before promoting the dry-blending as a suitable alternative to the melt-blending process. Methods Short chopped fibres were grinded as powders and dry-blended at a ratio of (0 − 10%) (w/w) with PCL polymer using hand and a shear mixer for 30 min, following a compression moulding process to produce bio-composite samples. Tensile, water contact angle, SEM, TGA, DSC and DMA tests and analysis were conducted. The dry-blended PCL/date palm fibre composites’ properties were compared with reported melt-blended samples’ results found in literature. Results Dry-blended samples showed an increase in tensile modulus values (up-to 20%) with fibre inclusion and these values were found close to the melt-blended samples in the literature. Tensile strength and strain values were reduced which could be related to the poor fibre/polymer interface. Fibre addition affected the thermal, thermo-mechanical and crystallisation processes in PCL polymer matrix. Conclusion Dry-blending is capable of producing bio-composites with a very comparable properties to melt-blended counterparts, although a more details study is needed to conduct in future. The results of this study, could be used carefully to design dry-blended PCL/date palm fibre bio-composites for possible packaging applications. The irregular fibre distribution in dry-blended samples could be improved in different ways which should be investigated in future. Graphical Abstract