Innovative Processes and Adhesives
This research axis aims to optimize panel manufacturing processes, including cost reduction, improve the performance of formaldehyde-based adhesives, and develop new adhesives sourced from bio-based materials or industrial process residues.
Project Identification: AXE2M4
Theme: Optimization – Processes
Status: In progress since January 2024
Details
Student: Dimitri Lor
Supervisor: Rémi Georges (Université Laval)
Co-supervisor: Mark Irle (École Supérieure du Bois - ESB, France)
Collaboration: Benoît Belleville (University of Melbourne), Fabrice Roussière (FPInnovations)
Industrial Partners: FPInnovations, Arbec Forest Products
Research Partners: Renewable Materials Research Centre (CRMR), ESB
Email: dimitri.lor.1@ulaval.ca
Description
Enhancing the quality of strands and reducing the percentage of fine particles have always been critical objectives in the continuous improvement efforts of oriented strand board (OSB) manufacturers. The significance of these two factors stems from their direct impact on panel mechanical properties, density, resin and wax consumption, raw material yield, and plant profitability. Additionally, the cutting parameters, such as knife configurations, counter-knives, incision knives, wear, cutting and feed speeds, and wood-feeding system performance, play a crucial role in strand quality during production.
This project aims to optimize strander cutting parameters to maximize the percentage of high-quality softwood and hardwood strands while minimizing the presence of fine particles for OSB manufacturing.
Student: Dimitri Lor
Project Identification: AXE2M5
Theme: Optimization – Processes
Status: In progress since September 2023
Details
Student: Thomas Legendre
Supervisor: Alain Cloutier (Université Laval)
Co-supervisor: Ahmed Koubaa (UQAT)
Collaboration: Aziz Laghdir (SEREX), Fabrice Roussière (FPInnovations)
Industrial Partners: FPInnovations, Arbec Forest Products
Research Partners: Renewable Materials Research Centre (CRMR), SEREX, UQAT
Email: thomas.legendre.1@ulaval.ca
Description
Oriented strand board (OSB) consists of three to five layers. During manufacturing, the strands in the surface layers are oriented lengthwise, while the core layers are oriented perpendicular to the surface layers. This orientation gives OSB panels superior bending strength compared to particleboard and comparable strength to plywood. In the context of continuous process improvement, better control of strand orientation by orienteers during the panel's formation would allow for maximizing panel properties. Additionally, it would provide flexibility to reduce the panel's density, thus reducing the volume of raw material required and, consequently, production costs.
This project aims to optimize the performance of orienteers to maximize the mechanical properties of OSB panels while reducing their mass.
Student: Thomas Legendre
Project Identification: AXE2M15
Theme: Processes - Adhesives
Status: Not Started (start planned for 2025)
Details
Student: To be determined
Supervisor: Véronic Landry (Université Laval)
Co-supervisor: To be determined
Collaboration: Ingrid Calvez (Université Laval)
Industrial Partners: Arbec Forest Products, Tafisa, Uniboard
Research Partners: Renewable Materials Research Centre (CRMR), Vinavil
Email: Not specified
Description
This project explores the potential of latex-based adhesives that are colloidal dispersions of polymer particles, such as polyvinyl acetates (PVAc) and polyacrylics, for use in wood-based composite panels. PVAc, commonly used in the materials industry, offers good adhesion to various substrates while being relatively safe and having a low environmental impact. However, its performance is limited in humid conditions or high temperatures (over 70°C). On the other hand, polyacrylate dispersions are characterized by their excellent resistance to water, alkalis, and corrosion and their transparency. Initially, studies will be conducted to select the most suitable latexes (solid content, glass transition temperature, etc.). Next, integrating bio-based polymers will be envisaged to enhance the durability and performance of these adhesives (moisture resistance and adhesion strength) while reducing their environmental impact.
Project Identification: AXE2M16
Theme: Optimization – Adhesives
Status: Not Started (start planned for 2025)
Details
Student: To be determined
Supervisor: Véronic Landry (Université Laval)
Co-supervisor: To be determined
Collaboration: Ingrid Calvez (Université Laval)
Industrial Partners: Arbec Forest Products, SACOPAN, Tafisa, Uniboard
Research Partners: Renewable Materials Research Centre (CRMR)
Email: Not specified
Description
This project focuses on the development of bio-based adhesives using tannins from the boreal forest. These tannins, extracted and purified in our laboratory, will be studied as part of an adhesive system. Tannin-based resins can form a cross-linked structure by self-condensation or cross-linking. Although resins obtained by autocondensation are suitable for indoor applications, their resistance to water and swelling is limited. On the other hand, resins cured with cross-linking agents offer better mechanical and chemical performance. Various alternative curing agents to formaldehyde, such as hexamethylenetetramine, tris(hydroxymethyl)nitromethane, glyoxal and glutaraldehyde, will be studied to assess their reactivity with boreal forest tannins. We will also analyse their performance in wood-based composite panels, such as water resistance, internal bonding and volatile organic compound emissions.
Project Identification: AXE2DOC2
Theme: Optimization – Processes
Status: In progress since January 2024
Details
Student: Johana Gaitan Alvarez
Supervisor: Alain Cloutier (Université Laval)
Co-supervisor: Véronic Landry (Université Laval)
Collaboration: Ahmed Koubaa (UQAT), Aziz Laghdir (SEREX), Rosilei Garcia (Université Laval)
Industrial Partner: SACOPAN
Research Partners: Renewable Materials Research Centre (CRMR), SEREX, UQAT
Email: johanna.gaitan-alvarez.1@ulaval.ca
Description
SACOPAN is the sole Canadian facility producing high-density embossed door panels for interior door manufacturing. Door panels, also known as "skins," are the outer parts that cover embossed interior doors, both front and back. The product is primarily sold in North America through Masonite, one of the world's largest door manufacturers. Sacopan's panels are made from softwood wood fibers and are coated with two layers of water-based primer, which the company aims to reduce consumption.
This project aims to develop a hot pressing strategy to improve the surface density of embossed door panels and optimize finish primer use. The effect of various pressing parameters on the density profile of the panels will be evaluated. Surface characterization of the panels through contact angle measurement (wettability and surface free energy), 3D optical profilometry (roughness), and high-resolution optical microscopy by Keyence (surface structure) will also be studied. The correlation between panel surface density, primer adhesion quality, and surface properties will be investigated.
Student: Johanna Gaitan Alvarez
Project Identification: AXE2DOC3
Theme: Innovative Adhesives
Status: In progress since September 2024
Details
Student: Lucie Dehon
Supervisor: Véronic Landry (Université Laval)
Co-supervisor: To be determined
Collaboration: Ingrid Calvez (Université Laval)
Industrial Partners: SACOPAN, Tafisa, Uniboard
Research Partners: Renewable Materials Research Centre (CRMR)
Email: lucie.dehon.1@ulaval.ca
Description
The wood-based composite panel industry is an ever-evolving sector that must continually adapt to consumer demands and regulations regarding volatile organic compound emissions. Consumers increasingly seek products with a low environmental impact that are also safe for health. However, adhesives used in the manufacturing of these panels typically consist of synthetic resins and fossil-derived materials, some of which, such as formaldehyde, are classified by the World Health Organization as carcinogenic to humans and animals.
This project aims to develop a bio-based adhesive with properties comparable to those currently used at a reasonable cost and without formaldehyde emissions. Renewable resources used in this project will be proteins derived from industrial by-products. Several methods will be employed to overcome the drawbacks associated with protein-based adhesives, such as low water resistance and weak adhesion strength. For example, denaturation, which enhances the accessibility of amino acid side groups hidden within the internal protein structure, or modification through the reaction between a crosslinking agent and the active protein groups, may be used. Extraction, modification, and chemical analysis of proteins will be carried out, and their potential in bio-based adhesive formulations will be studied. The performance of bio-based adhesives will be compared to their petroleum-based counterparts.
Student: Lucie Dehon
Project Identification: AXE2DOC4
Theme: Optimization – Processes
Status: In progress since January 2024
Details
Student: Ndeye Khady Ndiaye Lo
Supervisor: Alain Cloutier (Université Laval)
Co-supervisor: Aziz Laghdir (SEREX)
Collaboration: Fabrice Roussière (FPInnovations), Rosilei Garcia (Université Laval)
Industrial Partners: FPInnovations, SACOPAN, Tafisa, Uniboard
Research Partners: Renewable Materials Research Centre (CRMR), SEREX
Email: ndeye-khady-ndiaye.lo.1@ulaval.ca
Description
Hot pressing is one of the most critical stages in the panel manufacturing process. It consolidates the mat to achieve the desired panel density and thickness, polymerizes the binder, and stabilizes the panel under heat and pressure. However, this stage is also a significant bottleneck in the panel manufacturing process due to the pressing time, which dictates production speed in the factory, and the high energy consumption, leading to high costs and environmental impacts.
This project aims to enhance heat transfer within the mat to reduce the hot pressing time for panels. Various strategies and pressing times will be considered in this study. Thermal conductivity and factors influencing it, such as density, porosity, moisture content, temperature, and particle or fiber size, will be investigated. Thermally conductive (nano)materials may also be explored to improve heat transfer. Part of the project will involve modeling heat and mass transfer within the mat during hot pressing.
Student: Ndeye Khady Ndiaye Lo
Project Identification: AXE2DOC6
Theme: Innovative Adhesives
Status: In progress since January 2024
Details
Student: Ilias El Ouahabi
Supervisor: Véronic Landry (Université Laval)
Co-supervisor: Diane Schorr (FPInnovations)
Collaboration: Maria Zakharova (Kemitek), Ingrid Calvez (Université Laval)
Industrial Partners: FPInnovations, SACOPAN, Tafisa, Uniboard
Research Partners: Renewable Materials Research Centre (CRMR)
Email: ilias.elouahabi.1@ulaval.ca
Description
The wood-based composite panel industry is an ever-evolving sector that must continually adapt to consumer demands and regulations regarding volatile organic compound emissions. Consumers increasingly seek products with a low environmental impact that are safe for health. However, adhesives typically used in manufacturing these panels consist of synthetic resins and fossil-derived materials, some of which, such as formaldehyde, are classified by the World Health Organization as carcinogenic to humans and animals.
Saccharide-based resins are promising renewable alternatives to petroleum-based ones. However, they are underutilized due to their low adhesive strength and poor water resistance. The esterification of saccharide hydroxyl groups is an effective solution to improve their adhesive strength and water resistance. Therefore, esterification reactions will be studied, involving saccharides from various sources (e.g., cellulose, starch, sugars, etc.) and carboxylic acid (e.g., citric acid, lactic acid, etc.) to form the corresponding ester bond. The esterification reaction will be optimized, and the adhesive's performance for wood-based composite panels will be evaluated, considering mechanical properties and water resistance.
Student: Ilias El Ouahabi
Project Identification: AXE2DOC7
Theme: Innovative Adhesives
Status: In progress since January 2024
Details
Student: Sayed Saman Vakili
Supervisor: Véronic Landry (Université Laval)
Co-supervisor: Papa Diouf (SEREX)
Collaboration: Ahmed Koubaa (UQAT), Ingrid Calvez (Université Laval)
Industrial Partners: SACOPAN, Tafisa, Uniboard
Research Partners: Renewable Materials Research Centre (CRMR), SEREX, UQAT
Email: seyed-saman.vakili.1@ulaval.ca
Description
The wood-based composite panel industry is an ever-evolving sector that must continually adapt to consumer demands and regulations regarding volatile organic compound emissions. Consumers increasingly seek products with a low environmental impact that are safe for health. However, adhesives typically used in manufacturing these panels consist of synthetic resins and fossil-derived materials, some of which, such as formaldehyde, are classified by the World Health Organization as carcinogenic to humans and animals.
This project focuses on the development of bio-based adhesives using locally sourced tannins. Commercial tannins are already used for adhesive formulation and are mainly derived from tropical species (mimosa, quebracho). However, tannins from the boreal forest are underutilized due to their low reactivity. The project will explore using green extraction processes and optimized purification steps to enhance the quality of tannin extracts (homogeneity and reactivity). A tannin-based adhesive system will then be studied and applied to wood-based composite panels. The performance of bio-based adhesives will be compared to their petroleum-based counterparts.
Student: Seyed Saman Vakili
Project Identification: AXE2M8(DOC)
Theme: Optimisation - Processes
Status: Not Started (start planned for September 2024)
Details
Student: Fadoua Slouli
Supervisor: Ahmed Koubaa (UQAT) | Université de Jendouba (Tunisie) - co-supervision
Co-supervisor: To be determined
Collaboration: To be determined
Industrial Partners: FPInnovations, Arbec Forest Products, Tafisa, Uniboard
Research Partners: Renewable Materials Research Centre (CRMR), University of Jendouba
Email: Not specified
Description
Some categories of construction and demolition (C&D) waste currently do not benefit from any recovery process, and the preferred options remain landfilling or incineration, which are considered the only disposal methods. However, many of these materials have biodegradable characteristics, offering the possibility of being composted or subjected to bioremediation processes, thus constituting an alternative recovery. Among the components of the wood waste stream from C&D are various wood-based composite materials, such as medium-density fibreboard (MDF), particleboard, plywood, oriented strand board (OSB), and melamine-based laminated panel. However, the presence of formaldehyde in the resin significantly hinders the potential for recovery of these panel residues. Landfilling of these wastes can leach toxic compounds into soils, while their incineration can generate pollutant gas emissions, contributing to the increase of greenhouse gases (GHG).
This project aims to develop an alternative to traditional disposal methods, such as landfilling and incineration, by developing biological processes for the treatment of wood-based composite panel residues. Particular attention will be paid to the bioremediation potential offered by bacteria and fungi responsible for wood decomposition to eliminate contaminants in these panels. It will be essential to study the enzymatic capacities of microorganisms, which are necessary to break specific chemical bonds. This biological action will be optimized under specific environmental conditions, including temperature, humidity, pH, and oxygen.
Project Identification: AXE2DOC12
Theme: Processed - Innovative Adhesives
Status: In progress since October 2024
Details
Student: Laura Chrétien
Supervisor: Véronic Landry (Université Laval)
Co-supervisor: To be determined
Collaboration: Ingrid Calvez (Université Laval)
Industrial Partners: SACOPAN, Tafisa, Uniboard
Research Partners: Renewable Materials Research Centre (CRMR)
Email: laura.chretien.1@ulaval.ca
Description
In this project, we prioritize using renewable resources, particularly proteins derived from industrial by-products. Proteins, as natural polymers rich in diverse functional groups, can interact with wood through multiple physicochemical interactions. They are promising raw materials for environmentally friendly adhesives, free from formaldehyde. However, their low moisture resistance is a significant challenge in using protein-based adhesives for wood products. This project's envisioned strategy aims to enhance the entanglement of polypeptide chains. Exposing reactive functional groups such as carboxyl, amino, hydroxyl, and sulfonamide groups is essential to achieve this. Thus, treatment with soluble alkalis or enzymatic, etc., will be necessary to expose and disperse more amide functional groups, thereby maximizing adhesion to the wood surface. Several parameters will be investigated, including hydrophobic chain length, hydrophobicity, amino acid sequence, and chemical composition, which influence adhesion. This project represents a significant step toward sustainable and innovative solutions in the wood-based composite panel industry.
Student: Laura Chrétien
Project Identification: AXE2M14(DOC)
Theme: Processes- Adhesives
Status: In progress since October 2024
Details
Student: Manon Mestre
Supervisor: Véronic Landry (Université Laval)
Co-supervisor: To be determined
Collaboration: Ingrid Calvez (Université Laval)
Industrial Partners: SACOPAN, Tafisa, Uniboard
Research Partners: Renewable Materials Research Center (CRMR)
Email: manon.mestre.1@ulaval.ca
Description
The wood-based composite panel industry is an ever-evolving sector that must continually adapt to consumer demands and regulations regarding volatile organic compound (VOC) emissions. Consumers increasingly seek products with low environmental impact and safety for health. However, formaldehyde emissions from conventional thermosetting resins, such as urea-formaldehyde (UF), phenol-formaldehyde (PF), melamine-ureaformaldehyde, and melamine-formaldehyde (MF), particularly in indoor environments, represent one of the most negative aspects of wood-based composite panels.
This project aims to enhance adhesive performance by incorporating additives to reduce formaldehyde emissions and improve moisture resistance. In line with increasingly stringent environmental standards regarding formaldehyde emissions, our goal is to modify existing adhesive systems by integrating formaldehyde sensors capable of capturing free formaldehyde. Preferred additives for this project will have a bio-based origin. Various types of natural additives will be explored, including tannins, celluloses (e.g., nanocellulose, microcellulose, and cellulose filament), as well as lignins, (poly)phenols, and more. Furthermore, we consider functionalizing these additives with amine groups, such as aminosilane (APTES). Notably, amine groups can react with both free formaldehyde in the resin and hydrolyzed formaldehyde in the panel. The potential of these additives will be assessed in adhesive formulation, as well as their impact on adhesive properties, including reactivity, internal bonding (IB) and water resistance.
Student: Manon Mestre
Project Identification: AXE2DOC14
Theme: Optimization – Processes
Status: Not Started
Details
Student: To be determined
Supervisor: Rémi Georges (Université Laval)
Co-supervisor: To be determined
Collaboration: To be determined
Industrial Partners: FPInnovations, SACOPAN, Uniboard
Research Partners: To be determined
Email: Not specified
Description
Fiber refining is one of the most critical steps in the MDF manufacturing process regarding energy consumption and fiber quality. The parameters of the disc refiner (e.g., refining plate geometry, refining disc spacing, and raw material retention time between discs) determine energy consumption. However, refiner energy performance also depends on (1) raw material characteristics, such as wood species, residue source (e.g., post-consumer wood residues, sawmill residues), residue type (chips, sawdust), raw material homogeneity and moisture content, and (2) pre-refining steaming conditions (e.g., steam pressure, temperature, and duration). All these variables also affect fiber quality, which significantly impacts panel properties. Consequently, optimizing fiber refining involves combining all these variables.
This project aims to optimize the refining parameters of a disc refiner to reduce energy consumption while maintaining a compromise with fiber quality. The fiber quality aspect may also involve different raw material sources, such as residues from primary processing and recycled wood residues, which are increasingly present in industrial processes.
Project Identification: AXE2DOC16
Theme: Processes - Adhesives
Status: Not Started (start planned for September 2024)
Details
Student: Sara Etminan
Supervisor: Véronic Landry (Université Laval)
Co-supervisor: To be determined
Collaboration: Ingrid Calvez (Université Laval)
Industrial Partners: SACOPAN, Tafisa, Uniboard
Research Partners: Renewable Materials Research Centre (CRMR)
Email: Not specified
Description
The wood-based composite panel industry is an evolving sector constantly seeking to adapt to consumer needs and regulations on volatile organic compound (VOC) emissions. The industry is constantly evolving to meet the needs of consumers who want products that have a low environmental impact and are safe for their health. However, the adhesives used in the conception of these panels are made of synthetic resins and petro-based materials, including formaldehyde, classified by the World Health Organization as carcinogenic for humans and animals.
Urea-formaldehyde (UF) resins are the most widely used adhesives due to their inexpensive raw materials, high reactivity, excellent wood adhesion, and more. However, they have a drawback related to the emission of free formaldehyde in composite panels. Lignin, derived from by-products of the paper industry, will be used as a substitute for UF resins. Two types of lignin will be studied: kraft lignin and hydroxymethylated lignin (lignin-H), along with their modification. The adhesive performance and panel properties will be analyzed, including internal bond strength (IB), water absorption, swelling, and density.
Project Identification: AXE2SPD1
Theme: Innovative Adhesives
Status: In progress since January 2024
Details
Postdoctoral Fellow: Anass Ait Benhamou
Supervisor: Véronic Landry (Université Laval)
Collaboration: Ingrid Calvez (Université Laval)
Industrial Partners: FPInnovations, SACOPAN, Tafisa, Uniboard
Research Partners: Renewable Materials Research Centre (CRMR)
Email: anass.ait-benhamou.1@ulaval.ca
Description
The wood-based composite panel industry is an ever-evolving sector that must continually adapt to consumer demands and regulations regarding volatile organic compound (VOC) emissions. Consumers increasingly seek products with a low environmental impact that are safe for health. However, adhesives typically used in manufacturing these panels consist of synthetic resins and fossil-derived materials, some of which, such as formaldehyde, are classified by the World Health Organization as carcinogenic to humans and animals. Urea-formaldehyde (UF) resins are the most commonly used adhesives due to their low-cost raw materials, high reactivity, excellent wood adhesion, and more. However, they have a drawback related to the emission of VOCs and free formaldehyde in composite panels.
This project aims to develop a bio-based adhesive for producing particleboards, enhancing their physical and mechanical properties and moisture resistance. Lignin, derived from by-products of the pulp and paper industry, will be used as a substitute for UF resins. This project will study two types of lignin: kraft lignin and hydroxymethylated lignin (lignin-H). Modification of lignin (e.g., depolymerization) may also be considered to improve its reactivity with the hardener. The performance of bio-based adhesives will be compared to their petroleum-based counterparts.
Postdoctoral Fellow: Anass Ait Benhamou
Status: In progress
Date: March 11 to August 30th 2024
Details
Student: Baptiste Giard
Program: Master, Materials Science and Engineering, École Polytechnique Fédérale de Lausanne (EPFL), Switzerland
Supervisor: Alain Cloutier (Université Laval)
Co-supervisor: Véronique Michaud (EPFL), Frédéric Pichelin (Haute école spécialisée bernoise - BFH, Switzerland)
Industrial Partners: Arbec Forest Products
Research Partners: Renewable Materials Research Centre (CRMR), EPFL, BFH
Email: baptiste.giard.1@ulaval.ca
Description
Oriented Strand Boards (OSB) are widely used in the construction industry for their versatility and strength. However, continuous improvement of their mechanical properties remains a major goal for panel manufacturers. In this context, this project focuses on optimizing the orientation of wood strands in OSB panels to improve their mechanical strength and overall performance. This project aims to develop a method for analyzing the strand orientation in OSB and to evaluate the effect of strand orientation on bending properties, i.e., modulus of rupture and modulus of elasticity.
Student: Baptiste Giard
Status: Not started
Date: To be determined
Details
Student: To be determined
Program: Not specified
Supervisors: Alain Cloutier (Université Laval)
Industrial Partners: SACOPAN
Research Partners: Renewable Materials Research Center (CRMR)
Courriel: Not specified
Description
The intern will be required to familiarize himself with the manufacturing process of medium-density fiberboard (MDF) to produce interior doors, identify the various issues related to fine particle emissions at different stages of the manufacturing process, and find solutions to reduce or eliminate these emissions. His task will be to (a) develop a safe sampling method to analyze the composition of the dryer emissions; (b) document the volume of particles emitted daily; (c) identify the sources of fine particle emissions inside the plant; (d) propose solutions to reduce fine particle emissions in the work environment; and (e) make recommendations to reduce particle emissions based on the equipment and solutions available on the market.