The Development of Sugarcane Biocomposite for Household Product Design Application

UNIVERSITI TEKNOLOGI MARA

THE DEVELOPMENT OF
SUGARCANE BIOCOMPOSITE FOR

HOUSEHOLD PRODUCT DESIGN
APPLICATION

SHAHRIL BIN SAFIAN

Thesis submitted in fulfilment
of the requirement for the degree of Master of

Master of Art and Design

Faculty of Art & Design

May 2019

CONFIRMATION BY PANEL OF EXAMINERS

I certify that a Panel of Examiners has met on 21st December 2018 to conduct the
final examination of Shahril Bin Safian on his Master of Science thesis entitled “The
Development of Sugarcane Biocomposite for Household product Design Application”
in accordance with Universiti Teknologi MARA Act 1976 (Akta 173). The Panel of
Examiners recommends that the student is awarded the relevant degree. The panel of
Examiners was as follows:

Amer Shakir Bin Zainol, PhD
Associate Professor
Faculty of Art & Design
Universiti Teknologi MARA
(Chairperson)

Rusmadiah Bin Anwar, PhD
Associate Professor Technologies Dr.
Faculty of Art & Design
Universiti Teknologi MARA
(Internal Examiner)

Ahmad Zuhairi Bin Abdul Majid, PhD
Dr. (Industrial Design)
Deputy Dean (Academic)
Pusat Pengajian Seni
Universiti Sains Malaysia
(External Examiner)

Prof. Sr Ts Dr Haji Abdul Hadi
Haji Nawawi
Dean
Institute of Graduate Studies (IPSis)
Universiti Teknologi MARA
Date: 24th April 2019

ii



ABSTRACT

“Saccharum Officinarum” or (yellow cane) contributes to mass food production
industries. The use of this plant had become popular for mass production, for example
in raw sugar and juice production in Malaysia and the disposals of sugarcane produces
two-component that are bagasse and pith (BP). Unfortunately, BP had become an
issue due to the increased use of bins. As BP biocomposite has potential in design use
especially for mass manufacturing of product application hence this will reduce the
number of bins used for disposal purpose. In Malaysia, BP biocomposite potential in
mass manufacturing has been identified such as for producing flat particleboard.
Moreover, several BP biocomposite areas of use in mass production for industry
design manufacturing area namely automotive component, toys manufacturing,
packaging design, and product application production. In addition, examples of the
technologies applied to manufacture process in the large-scale factory are hot press,
injection moulding, and cool press. A new development besides these three processes
is using Hot Air Moulding Template (HAMP), which is suitable for use in
manufacturing household craft using BP biocomposite. Furthermore, laboratory tests
are conducted, for example on water absorption, thickness swelling, and flexure test.
As an expected outcome, this BP biocomposite can use as a potential towards of
product design application. These will be referring to Life Cycle Assessment
Framework (LCA) as a guideline on BP biocomposite mass manufacturing for
household craft product application before it will be ready to be produced.

iv

ACKNOWLEDGEMENT

Most of all thanks to Allah and UiTM Shah Alam for inviting me to the faculty of Art
& Design, Department of Industry Design, for me to pursue my studies in the field of
Master Research course. Many thanks to Dr Mohammad Azroll Ahmad, Dr Shahril
Anuar Bahari, Assoc. Prof. Ing. Dr Ing-. Oskar Hasdinor Hassan and Dr Haszlin
Shaharudin, as pillars that guide me in continuing my master level. Also in
recognition are personnel from the other streams: such as, from the Faculty of Applied
Science from UiTM Shah Alam.
The contribution from Applied Science that filled the need required for me in search
for more information and let me use several mechanical machines and chemicals
required for the manufacturing of BP biocomposite as household product application.
Most of all, to my mother, brother and sister who always pray and gave me the
strength to carry on with my journey to achieve my ambition.

v

TABLE OF CONTENTS Page
ii
CONFIRMATION BY PANEL OF EXAMINERS iii
AUTHOR’S DECLARATION iv
ABSTRACT v
ACKNOWLEDGEMENT vi
TABLE OF CONTENTS xii
LIST OF TABLES xv
LIST OF FIGURES
LIST OF SYMBOLS xxiii
LIST OF ABBREVATIONS xxv

CHAPTER ONE: INTRODUCTION 1

1.1 Background of Study 1

1.2 Manufacturing in Biocomposite Production 2

1.3 Potential of Sugarcane 3

1.4 The Context in Household Product Application and Product in Biocomposite 4

1.5 Processing The Bagasse And Pith (Bp) Biocomposite 5

1.6 Problem Statement 6

1.7 Research Objective 8

1.8 Context and Scope of Research 9

1.8.1 Context 9

1.8.2 Significant Of Study 10

1.9 Aims and Research Question 11

1.9.1 Aims 11

1.9.2 Research Question 11

CHAPTER TWO: LITERATURE REVIEW 13
2.1 Overview of Main Rules of The Lean Manufacturing Process 13

vi

2.1.1 The Rules of Sustainable Green Product Designer towards Mass

Manufacturing Design 13

2.1.2 The Element of Sustainable Design (EoSD) via Mass Manufacturing

Process for Industry Design 16

2.1.3 The Design for Sustainable (DFS) via Product Design using Waste BP

Biocomposite 18

2.1.4 The Designing for Environment (DfE) Towards Product Design 20

2.1.5 The Life Cycle Assessment (LCA) Towards of Manufacturing Proce

23

2.1.6 The End of Life Cycle (EoF) for Mass Manufacturing Product Design

Production towards Gaining Economy Impact 26

2.1.7 The Overall Working for Design Mass Manufacturing Process 28

2.2 Overview of Previous Design with Similarity Between Industrial Design and

Applied Science Method Towards of Product Design using Natural

Biocomposite 31

2.2.1 The Previous Product Design Application use Natural Biocomposite as

a Design Process 32

2.2.2 The Similarity between Design Process and Material Manufacturing

Process 36

2.2.3 Basic Method and Experiment in the Manufacturing Process on Natural

Biocomposite as a Design Process 40

2.3 The Overview of Preparation, Experiment and Manufacturing Process for

Bagasse and Pith (BP) Biocomposite 47

2.3.1 The Basic Skill in Manufacturing Process using Natural Biocompos

48

2.3.2 The Sugarcane use as Biocomposite Material 50

2.3.3 The Properties of Natural Bagasse and Pith (BP) Component from

“saccharum officinarum” (yellow cane) 53

2.3.4 The Slow Design Experiment on Treatment Process using Boiling and
“Sodium Chloride” (NaCl) as to Loose “lignin” Contain Inside of

Yellow Cane 56

2.3.5 The Slow Design Experiment on Sun Dried and Air Dried via

Decreasing Moisture Content of yellow cane 58

vii

2.3.6 The Slow Design Experiment on Oven Dried for Decreasing Moisture

Content and Blending Process Dry Bagasse and Pith from Yellow Cane

60
2.3.7 A “Polyvinyl Alcohol” (PVA) as Adhesive use for Product Application

62

2.3.8 The Mathematical Formulas Use for Fabrication of Product

Application 65

2.3.9 The Development Technique of Low Technology for Manufacturing

Process using Hot Air Moulding Template (HAMP) as Low Cost for

Small Scale Mould Product Application 67

2.4 Overview of Design Process for Craft Household Product Application by using

Hot Air Moulding Template (HAMP) as Low Technology Mass Manufacturing

Process 74

2.4.1 The Different of Existing Technique Manufacturing Process for Low

Technology for Craft Household Product in Rural Small Scale

Industries 75

2.4.2 The Benefit of Development Hot Air Curing and Drying Technology

by using Hot Air Moulding Template (HAMP) as Potential use in

Manufacturing Process for Rural Small Craft Industries 77

2.4.3 The Basic Design Process using Bagasse and Pith (BP) Biocomposite

as Material for Manufacturing Craft Household Product using

Technical Drawing based on 3D Platform 79

CHAPTER THREE: METHODOLOGY 81

3.1 Overview of Research Methodology 81

3.2 The Preparation Material Process for Drying Experiment 82

3.2.1 The Slow Design Experiment Based on Flow Chart Process for Drying

Raw Bagasse and Pith (BP) 83
3.2.2 The Collection of Raw “saccharum officinarum” (yellow cane) 83

3.2.3 Slow Design Experiment on Conditioning Collection Raw yellow cane

84
3.2.4 Slow Design Experiment for Loose “lignin” on yellow cane using

Boiling 84

viii

3.2.5 Slow Design Experiment for Loose “lignin” on yellow cane using

“Sodium Chloride” (NaCl) Treatment 85

3.2.6 Slow Design Experiment using Sun Dried and Interior Air for Dries

Wet Bagasse and Pith (BP) Component from yellow cane 86

3.2.7 Slow Design Experiment using Oven Dried Machine for Wet BP

Component from yellow cane 87

3.2.8 Slow Design Experiment using Blending and Packaging Dried Bagasse
and Pith (BP) Components from “saccharum officinarum” (Yellow

Cane) 88

3.3 The Material Preparation Process For Hot Air Moulding Template (HAMP)

and Compressing Wire Mesh 88

3.3.1 Slow Design Experiment based on Flow Chart Process for

Manufacturing HAMP and Flattening Wire Mesh 89

3.3.2 Slow Design Experiment for Manufacturing Hot Air Moulding

Template (HAMP) Mould 91

3.3.3 Slow Design Experiment in Analysing HAMP Mould Design using

Eco Material Advisor (EMa) and Model Checker Software 91

3.3.4 Slow Design Experiment for Flattening Wire Mesh as Enhancement for

Fabrication BP Biocomposite 92

3.4 The Material Preparation Process for Fabrication BP Biocomposite From

Yellow Cane 93

3.4.1 Slow Design Experiment Based on Flow Chart Process for Fabricate

BP Biocomposite Board 94

3.4.2 Slow Design Experiment for Mixing Bagasse and Pith (BP)

Biocomposite Dough 95

3.4.3 Slow Design Experiment for Fabricating Bagasse and Pith (BP)

Biocomposite 96

3.5 The Preparation for Material Testing and Evaluating Potential Design for BP

Biocomposite 98

3.5.1 A Slow Design Experiment based on Flow Chart Experiment for BP

Biocomposite Block 99

3.5.2 A Slow Design Experiment for Material Testing for BP Biocomposite

Block Properties 100

ix

3.5.3 The Evaluation of Potential Design based on Previous Reviewers on

BP Biocomposite Product 100

3.5.4 The Method used in Manufacturing Process for Designing BP

Biocomposite Product Design Application 102

CHAPTER FOUR: RESULT AND DISCUSSION 103

4.1 Overview Of Overall Of Result And Discussion Through Slow Design

Experiment 103

4.2 Conceptual Framework 104

4.3 The Overview of Slow Design Experiment on Raw Material of Bagasse and

Pith (BP):- 240ᴼC Boiling Concentration and Treated with 48% Concentration

of “Sodium Chloride” (NaCl) 105

4.3.1 The Result of Slow Design Experiment in Loose “lignin” Content

Inside of Sugarcane by Boiling Treatment 106

4.3.2 The Result Discussion on Slow Design Experiment in Loose “lignin”

Content Inside of Sugarcane Pre-treatment Process using “Sodium

Chloride” (NaCl) 107

4.4 Overview Slow Design Experiment of Average Dry Percentage (Dry %) Result

for Bagasse using Sun-Dried and Oven Dried Machine 108

4.4.1 The Discussion of Slow Design Experiment for Dry Percentage (Dry

%) Result for Raw Bagasse and Pith From Sugarcane using Sun-Dried

109

4.4.2 The Discussion Slow Design Experiment: - in Receiving the Average

of Heat Force Dry Percentage (Dry %) Result to Dries Raw Bagasse of
Sugarcane “saccharum officinarum” using Oven Dried Machine 110

4.4.3 The Discussion Slow Design Experiment: - in Receiving the Average

of Heat Force Dry Percentage (Dry %) Result to Dries Raw Pith of
Sugarcane “saccharum officinarum” using Oven Dried Machine 112

4.5 The Overview on Detailing of Dry Percentage (Dry %) for Bagasse and Pith

(BP) Component From Yellow Cane: - as to Analyse The (Average Overall

Dry Loss For 22 Days+/-) using Determination Drying Reduction Percentage

Rate (DDR %) Formula 115

4.5.1 The Result Determination Dry Percentage Reduction Rate (DDR %)

for Bagasse Component from Yellow Cane 116

x

4.5.2 The Result Determination Dry Percentage Reduction Rate (DDR %)

for Pith Component from Yellow Cane 118

4.6 The Overview Of Distribution Frequency (Dν) Weight Gram (W/G) Dried For

Pith Sample and Bagasse Sample by using Oven Dried Machine for

“saccharum officinarum” (Yellow Cane) 119

4.6.1 Overall Distribution Frequencies (Dν) Movement of Bagasse

“saccharum officinarum” Dried Every 3 days 120

4.6.2 Overall Distribution Frequencies (Dν) Movement of Pith “saccharum

officinarum” Dried Every 3 days 122

4.7 The Overview in Analysing Particle Size of BP Biocomposite using Scanning

Electron Microscope (SEM) After Crushed 125

4.7.1 Scanning Electron Microscope (SEM) for Bagasse and Pith Fibres

from “saccharum officinarum” 125

4.8 The Overview of Weight Result Experiment 30cm×30cm Square Shape

Cutting Wire Mesh using Grinder Rotary Disc Power Tool Machine (GPTM)

and Diagonal Plier 126

4.8.1 The Weight Result Experiment 30 Cm × 30 Cm Square Shape 127

4.9 The Overview of Hand Lay-Up Technique in Manufacturing Process for

Fabricate BP Biocomposite Board 128

4.9.1 Formula Fabricate Bagasse and Pith Biocomposite Board 128

4.9.2 Result Fabricate Bagasse and Pith (BP) Biocomposite Board 131

4.10 The Overview of Optimization in Manufacturing Process for Bagasse and Pith

Biocomposite 132

4.10.1 The Optimization Hot Air Moulding Template (HAMP) 132

4.11 The Overview of Optimization Bagasse and Pith (BP) Biocomposite Dough

Process 133

4.11.1 The Optimization BP Biocomposite Dough 134

4.11.2 The Overall Detailing Result and Discussion Cause Curing Process for

BP Biocomposite 140

4.12 The Material Properties Strength Test for Bagasse and Pith (BP) Biocomposite

Board 142

4.12.1 The Discussion Water Absorption Experiment on Bagasse and Pith

(BP) Biocomposite 143

xi

4.12.2 The Discussion Thickness Swelling (TS) Experiment on Bagasse and

Pith Biocomposite 145

4.12.3 The Discussion Flexure Test (FT) Experiment on Bagasse and Pith

Biocomposite Result 150

4.13 Overview of Analysis On Life Cycle Assessment (Lca) Material Use In Hot

Air Moulding Template (HAMP) as Tool for Manufacturing Bagasse and Pith

(BP) Biocomposite 153

4.13.1 Modus Operandi Eco Material Advisor (EMa) Result for Hot Air

Moulding Template (HAMP) 153

4.13.2 Modus Operandi Model Checker Result for Hot Air Moulding

Template (HAMP) 156

4.14 Overview of Prototype Household Product Design 157

4.14.1 Sample 3D Prototype Household Product Design 158

4.14.2 Cutting Process for BP Biocomposite in Workshop Progress Work 159

CHAPTER FIVE:CONCLUSION AND RECOMMENDATION 161
5.1 Conclusion 161
REFERENCES 164
APPENDICES 215
AUTHOR’S PROFILE 253

xii

LIST OF TABLES

Tables Title Page

Table 2.2.2.1 A Table of Guideline for Slow Design through Scientific Method

38

Table 2.2.2.2 Basic Guideline for Working in Technical Line 39

Table 2.3.3.2 The Properties of Bagasse and Pith Sugarcane 55

Table 3.2.1 Preparation Material, Tools and Equipment for Drying Waste

Sugarcane 82

Table 3.3.1 The Material Preparation for HAMP Flattening Wire Mesh 89

Table 3.4.1 A Table of Preparation Material for BP Biocomposite Block 93

Table 3.5.1 A Table of Preparation Testing and Evaluating BP Biocomposite

Board 98

Table 4.4.2.1 Sample Weight of Dry% for “saccharum offficinarum” Bagasse A,

B, C and D 110

Table 4.4.3.1 Sample Weight of Dry% for “saccharum offficinarum” Pith A to H

112

Table 4.6.1.1 A Table Distribution Frequencies (Dν) of Bagasse “saccharum
Table 4.6.2.1
officinarum” 121

A Table of Distribution Frequencies (Dν) “saccharum officinarum”

Pith 123

Table 4.8.1.1 Weight Result Experiment 30 cm × 30 cm Wire Mesh Results

127

Table 4.11.1.7 Table of Result BP Biocomposite Board through the Curing Process

in Industrial Oven Drying Machine at the Faculty of Art & Design

138

Table 4.11.1.8 Table of Result BP biocomposite Board through the Curing Process

in Ceramic Kiln Chamber Faculty of Art & Design 139

Table 4.12.1.2 Table Result of Water Absorption for BP Biocomposite 144

Table 4.12.2.2 Table of Thickness Swelling Test for Three Similar Properties of

Bagasse and Pith Biocomposite with 50 mm × 50 mm 147

xiii

Table 4.12.3.2 Three samples of Flexure Test Result for BP Biocomposite 151
Table 4.13.1.1
Result of Eco Material Advisor Test (EMa) for Hot Air Moulding
Table 4.13.1.2
Table 4.13.1.3 Template 154

Table 4.13.1.4 End of Life (EoF): Analysed for Hot Air Moulding Template 154

Table 4.13.1.5 Energy Usage: Summary Hot Air Moulding Template (HAMP)

155
“Carbon Dioxide” (CO2) Footprint: Summary Hot Air Moulding

Template 155

Restriction of Hazardous Substance (RoHS) 156

xiv

LIST OF FIGURES

Figures Title Page

Figure 1.2.1 A Diagram of Domestic Solid Waste Statistics (Department of Solid
Figure 1.4.1
Figure 1.5.1 Waste Management), 2013, (M. H.I.M. Junoh, 2014) 3
Figure 2.1.1.1
LCA Framework Centralize on Manufacturing Process, (M.Rosen &
Figure 2.1.1.2
Kishawy, 2012) 4
Figure 2.1.1.3
Figure 2.1.2.1 An Overview of Sugarcane “saccharum officinarum” Structure via
Figure 2.1.2.2
Containing “lignin” in A “Cell Wall”, (Cesarino et al., 2012) 6
Figure 2.1.4.1
Figure 2.1.4.2 The D&B Design Criteria Framework for Life Cycle Assessment
Figure 2.1.5.1
Figure 2.1.5.2 Framework (LCA) via Mass Manufacturing, (May et al., 2016)

14

The Direction D&B Trend Criteria Framework For Mass

Development Mass Production For Furniture Component, (Chen et

al., 2015) 15

The Three Section Framework via Green Mass Manufacturing for

Industry Design, (Boetker et al., 2016) 15

The Element of Sustainable Design via Mass Manufacturing

Process for Industry Design, (Bocken et al., 2014) 16

The Variable Design Framework via the Development of

Sustainable Design Process for Industry Design Manufacturing,

(Kelley, 2015) 17

The Key concept of Product Design Process with combination DfS

and DfE to Evaluate, (Nutassey, 2014) 21

Natural Biocomposite Manufacturing Process using Low

Technology for Craft in Product Application, (Tung, 2012) 22

A Slow Design Flowchart for Biocomposite Material, (C.-H. Ko &

Chung, 2014) 24

A DoE Framework of Biocomposite Wood Processing

Manufacturing Experiment Task, (Chompu-inwai et al., 2015)

26

xv

Figure 2.1.5.3 Example of Ceramic Based on Mould Production using Low
Figure 2.1.6.1
Figure 2.1.7.1 technology Manufacturing, (Writer, 2015) 26
Figure 2.1.7.2
The Productivity Value Chain Supply Toward of Sustainable for
Figure 2.2.1.1
Figure 2.2.1.2 Mass Manufacturing Sector, (Jang, Park, Roh, & Han, 2015) 27

Figure 2.2.1.3 A Conceptual Framework for Experimental Design Mass
Figure 2.2.3.1
Figure 2.2.3.2 Manufacturing Process, (van Turnhout et al., 2014) 28
Figure 2.2.3.3
Figure 2.2.3.4 The Input Of Conceptual Research Framework Via Output and Task

Figure 2.3.1.1 In Lab Scale Experiment, cited Penfield et al., 2014, (Murat Aydin,
Figure 2.3.1.2
2015) 30

Examples of Bagasse and Pith (BP) Biocomposite Use for Car

Interior, (Babu, 2018) 33

Example of Bagasse and Pith Biocomposite Product, a) Disposal

Cups, b) Biodegradable Disposal Bags, c) Pen With Cover Pens, d)

Mini Shaver for Men or Women Tools Kit and e) Biodegradable

Food Packaging, (Satyanarayana, Arizaga, & Wypych, 2009b)

34

Example of BP biocomposite use to design Break Pad for Car,

(Rashid et al., 2017) 36

Example for Manufacturing Natural Biocomposite from Bagasse

Biocomposite, (Chockalingam, 2014) 41

Example Flow Chart Process on using Pre-Treatment and Washed in

Slow Design Experiment for Fresh Bagasse, (Lan et al., 2011) 42

Technique on Applying Forming Mild Steel Plate (MSP), (Swift &

Booker, 2003) 44

A Guideline Direction For Industrial Design And Applied Science

Toward of Experiment In Potential Design In Product Design, (R.

Byron Pipes et al., 2004) 46

The Example of Natural Biocomposite Flowchart for Mass

Manufacturing Flat Board, (Dahy, 2017) 48

The Example of Mixing Natural Biocomposite Cork Granule and

Hemps in Manufacturing A Flat Board: a) Fresh Block Placing

Under Mould and b) A Samples of Cutting Blocks That Had Curing,

(Sassu et al., 2016) 50

xvi

Figure 2.3.2.1 The Example of BP Biocomposite Board using “saccharum
Figure 2.3.2.2
Figure 2.3.2.3 officinarum”, (Barbu et al., 2017) 51
Figure 2.3.3.1
Example Technique in Manufacturing Process Hemps Biocomposite
Figure 2.3.3.3
Figure 2.3.4.1 using Hand Lay Up Technic, (Benfratello et al., 2013) 52
Figure 2.3.6.1
Figure 2.3.6.2 Wasara Tableware form Bagasse Biocomposite, (Okusa & Ogusu,

Figure 2.3.7.1 2014) 53
Figure 2.3.7.2
Figure 2.3.8.1 Zoom Into a “Xylem” Show ‘M’ as a “Meta Xylem” and “Epithelial
Figure 2.3.9.1
Cell” ‘E’ and “Proto Xylem” Retake Covers to Control All over the

“Vascular Bundle” System to Produce “lignin”, Engineering, (n.d.)

54

The Detail Structure of Natural Tree Sugarcane “saccharum

officinarum”, (Mohammadinejad et al., 2016) 55

The Detailing of Green Components for Sugarcane “saccharum

officinarum”, (Pereira et al., 2011) 57

Dry Bagasse and Pith Component from “saccharum officinarum”:

a) Dry Bagasse Not Yet Crushing, and b) Pith Blending, (A. K.

Varma & Mondal, 2016) 60

Example of Sample Result of Moisture Drying Cassava Fibers and

Content Percentage (Mc %) for Cassava Natural Biocomposite: a)

Cassava Drying Sample, and b) MC Graph Drying Sample,

(Baharuddin et al., 2016) 61

Example “Polyvinyl Alcohol” (PVA) Manual Mixing Process Low

Technology Production for “Slime” as Anti-Stress Ball,

(Romanowski, 2018) 63

Example of Low Technology for Sustainable Development

Manufacturing Process using Hand Lay Up Technic, (Chowdhury et

al., 2015) 64

Example Process of Handling Hand Manually Mixing Method for
Natural Cashew Biocomposite Material using “Polyvinyl Alcohol”

(PVA) Solution, (Junior et al., 2014) 67

A Structure of Arrangement Natural Biocomposite for Mass

Production, (Jareteg et al., 2016) 68

xvii

Figure 2.3.9.2 The Development of Hot Air Technology using Stainless Steel

Figure 2.3.9.3 Template: a) Top View Stainless Steel and b) Compression

Figure 2.3.9.4 Technique, (Jokar & O’Halloran, 2013) 69
Figure 2.3.9.5
Figure 2.3.9.6 Example Low-Cost Technology Development Manufacturing

Figure 2.3.9.7 Process using Hand Lay Up Technic Mass Manufacturing Process:
Figure 2.4.2.1
Figure 2.4.3.1 a) Placing Mould, b) Rolling using Roller and c) Closing the Lid

Figure 2.4.3.2 With Bolt and Nut, (Rao, Sri, & Ramanarayanan, 2016) 71

Figure 3.1.1 Example of 3D CAD Assembly for Manufacturing Moulding
Figure 3.2.2.1:
Template, (Mills & Tatara, 2016) 71
Figure 3.2.4.1
A Development Concept of Air Kiln Drying Process for Ceramic
Figure 3.2.7.1
Production, (Venkatesh & Venkateswarlu, 2013) 72

A Sample of Flexural Test (FT) for BP Biocomposite Material for

Particle Board Production, (Belini, Ugo Leandro, Ugo Leandro

Belini, Ângela do Valle and Poliana Dias de Moraes, 2015) 73

An Example Sample of Water Absorption (WA) Test Effect for

Cotton Natural Biocomposite, (G. Huang & Sun, 2007) 73

Example Air Technology Flow for Natural Food Dryer Kiln

Chamber by Patil and Shukla 1988, (Chua & Chou, 2003) 77

Example 3D View Application in Designing Product Application: a)

Stereo lithograph Parts (STL), b) Editing, c) Line Drawing and c)

Material Setup, (Strauss, 2013) 80

Example Low Technology Manufacturing Process as Craft Product

Application: from Natural Fibre Biocomposite: a) Flat Heated

Coaster, and b) Decoration Ceramic, (Parisi & Stefano, 2017) 80

Research Methodology 82

Fresh Bagasse and Pith (BP) Component from Sugarcane
“saccharum officinarum” are collected from Night Market Bandar

Baru Ampang, Selangor 84

The Preparation Equipment and Apparatus for Slow Design

experiment through Boiling Method for Fresh BP from Sugarcane:

a) Bagasse and b) Pith 84

BP Component Insert into Oven Dried Machine with 100 ᴼ C less

than 4 weeks+/- 87

xviii

Figure 3.2.7.2 Small Sets of Dry Testing Cup for collecting the movement Dry%
Figure 3.3.1.1
Figure 3.3.3.1 without Crush for four samples of Bagasse and eight samples of Pith

Figure 3.4.1.1 from “saccharum officinarum” 87
Figure 3.5.1.1
Figure 3.5.3.1 Slow Design Experiment for Manufacturing for HAMP Mould and

Figure 4.2.1 Compressing Wire Mesh 90
Figure 4.3.1.1
Figure 4.3.2.1 Analysing Hot Air Moulding template (HAMP): a) Eco Material

Figure 4.5.1.1 Advisor User Interface for Analyse Material and Units Item and b)
Figure 4.5.2.1
Figure 4.7.1.1 PTC Model Checker from Pro-Engineer Software in Analyse the

Quality Design Mould Manufacturing Process 92

A Slow Design Experiment based on Flow Chart Process for

Fabricate BP Biocomposite Block 94

A Slow Design Experiment based on Flow Chart Process for

Experiment BP Biocomposite 99

Drawing Process: a) A Sample Sketches View Design BP

Biocomposite Board use for Pot Liner and Glass Coaster

Application and b) BP Biocomposite Board for Product Application

as Development Manufacturing Process 101

The Design Framework for Product Design Application Mass

Production using Low Technology Manufacturing Process 104

A Boiling Method Applying for Reducing “lignin” Contain in 4

Hour+/- 240 ᴼ C+/- with a Water Pipe 106

A Treatment Process Bagasse and Pith for 3 Days to Loose a
“lignin” Contain Inside a Container Mixing with “Sodium
Chloride” (NaCl) and Water Pipe and Ready for Strainer using

Basket 108

Determination Dry Reduction Percentage Rate (DDR %) for
“saccharum officinarum” samples Bagasse A, B, C, and D 116

Determination Dry Reduction Percentage Rate (DDR %) for
“saccharum officinarum” sample Pith A, B, C, D, E, F, G and H

118
A Photo of Bagasse Component 300 µm zooming from “saccharum
officinarum” (Yellow Cane) Particle Length is 139 µm to 424 µm:

a) Pith Biocomposite 139 µm, b) Pith Biocomposite 303µm, and c)

Pith Biocomposite 424µm 126

xix

Figure 4.7.1.2 A Photo of Pith Component 300µm zooming from “saccharum
officinarum” (Yellow Cane) particle Length is 154 µm to 324 µm

using Scanning Electron Microscope Machine (SEM), a) Pith

Component Particle Length Size 154 µm, b) Pith Biocomposite 233

µm, c), Pith Biocomposite Component, 324 µm 126

Figure 4.9.1.1 A Technical Drawing Hot Air Moulding Template (HAMP) Mould

30 cm × 20 cm for Per Sample Unit 129

Figure 4.9.1.2 The Area for Fabricate Bagasse and Pith Biocomposite Dough for

Per-Sample Board 130

Figure 4.9.2.1 Finding Through First Experiment Attempt via Manufacturing BP

Biocomposite Board using Ceramic Kiln Chamber and Industrial

Oven Dried Machine: a) Air Pores Effect after 3 hours and 30
minutes and 180 ᴼ C, b) Rises Effect after 4h+/- and 220 ᴼ C, c) A

Burst Effect Through Industrial Oven Dried Machine after 2 hours

and 30 minutes, d) A Manufacturing BP Biocomposite Board Over

Burn after 4h+/- and 180ᴼ C, and e) Half Cured Effect 2h 30 minutes

and 180ᴼ C 132

Figure 4.10.1.1 A Development of Hot Air Moulding Template (HAMP) via using

Arc Welding Technique via Reducing Leakage, Bursting Effect, and

Rise Effect: a) A-Frame had Weld using Arc Weld and b) A

development of HAMP Mould 133

Figure 4.11.1.1 A Throwing Method Applying for BP Biocomposite Dough for 10

minutes+/- 134

Figure 4.11.1.2 Method for Spraying with Wax Paper and Placing Paper Wax via on

top of Hot Air Moulding Template (HAMP): a) spray the HAMP

Mould using Grease, b) Place Wax Paper on top of HAMP mould, c)

Close and Arrange Wax Paper onto Surface, d) Spray Again on top

Wax Paper Surface, e) Flatting Wax Paper Surface with Hand Push

Gently and f) used Cutter Blade by Slicing the Paper Wax Excessive

134

Figure 4.11.1.3 Method of Removing Water Excessive, Peeling Wax Paper and

Drying for 1 Hour+/- Frontside and Backside: a) Cool Press for 1

Hour, b) Peeling Wax Paper Backside and Frontside, and c) Air

drying for 1 Hour+/- 135

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Figure 4.11.1.4 Curing Process via using Ceramic Kiln Chamber in 180 ᴼ C for

2hours+/- to 4 hours+/- and Blower Process for 30 minutes for

Frontside and Backside: a) A Hot Air Moulding Template (HAMP)

mould Enter in Ceramic Kiln Chamber, b) Curing Process for 2

hours to 4 Hour+/- and c) Blowing via BP Biocomposite for 30

minutes Backside and Frontside 136

Figure 4.11.1.5 A 30 cm × 20 cm BP Biocomposite Board via Curing in Ceramic
Kiln Chamber in 3 hours and 30 minutes via 180 ᴼ C and Waste of

BP Biocomposite Dough from "saccharum officinarum" had

wrapped via using Stretching Plastic 136

Figure 4.11.1.6 Cool Press for Three Days for 72 Hours Room Temperature 30 ᴼ C

137

Figure 4.11.2.1 BP Biocomposite Curing using in Industrial Oven Dried Machine:

A) BP Biocomposite Curing for 2 Hours 30 Minute, B) BP

Biocomposite Curing For 3 Hours 30 Minute and C) BP

Biocomposite 4 Hours 140

Figure 4.11.2.2 BP Biocomposite Curing using Ceramic Kiln Chamber: A) BP

Biocomposite Curing for 2 Hours 30 Minutes, B) BP Biocomposite

Curing for 3 Hours 30 Minute And C) BP Biocomposite 4 Hours

141

Figure 4.12.1.1 A Water Absorption Test Set-Up Experiment BP as Labelled

Biocomposite A, BP biocomposite B and Biocomposite C 143

Figure 4.12.2.1 The Apparatus Set-Up using Veneer Calliper for Per- Sample of 50

mm × 50 mm × 12 mm 145

Figure 4.12.3.1 Flexure Test Graph for Three Sample of BP biocomposite 150

Figure 4.14.1.1 Rendering Experiment by using Maxwell Render for 2 Hours in

Perspective View 159

Figure 4.14.1.2 Rendering Setup Screen for Maxwell Render had Setup for 25

Sampling Render for 2 Hour or 120 Minutes 159

Figure 4.14.1.3 Rendering Experiment by using Maxwell Render for 2 Hours in

Environmental View 159

Figure 4.14.2.1 Cutting Area for BP Biocomposite for Prototype Drink Glass

Coaster 159

Figure 4.14.2.2 The BP Biocomposite Cutting by using Band Saw Machine 160

xxi

Figure 4.14.2.3 The Design for BP Biocomposite Board That had been cut by using
Band Saw Machine A Coaster Prototype Drink Glass Coaster
160

xxii

LIST OF SYMBOLS

Symbols (Plus)
+ (Times)
× (Diameter)
Ø (Divided)
÷ (Equal)
= (Foot)
’ (Plus-Minus)
+/- (Square Root)
(Cubic Root)
2 (Degree Celsius)
(Percentage)
3 (Centimetre)
(Flexural Test)
ᴼC (Gram)
% (Height)
cm (Milijoule)
FT (Kilogram per Meter Cubic)
g (Length)
H (Moisture Content Percentage)
Mj (Mega Pascal)
Kg/m3 (Meter)
L (Millimetre)
MC% (Millimetre per Cubic)
MPa (Newton)
m (Oxide)
mm (Potential Hydrogen)
mm3 (Tread)
N (Time per Hours)
O (Tons)
pH
T
T/Hr
Ton

xxiii

TS (Thickness Swelling Test)

W (Width)

W0/g (Dry Weight Gram)

W0/g Dry% (Dry Weight Gram Percentage)

Wg (Weight Gram)

WA (Water Absorption Test)

WA% (Water Absorption Percentage)

xxiv

LIST OF ABBREVIATIONS

Abbreviations

3DS file (3Ds Max File)

ASTM (American Standard Test Material)

BP (Bagasse and Pith)

CAD (Computer Aided Design)

CO2 (Carbon Dioxide)

D&B (Design and Build)

DK (Drying Kiln)

DfE (Design for Environment)

DfS (Design for Sustainable)

DoE (Design for Experiment)

EMa (Eco Material Advisor)

EoF (End of Life Cycle)

EoSD (Element of Sustainable Design)

FG (Fiber Glass)

FGDM (Floor Gear Drill Machine)

FMPC (Foot Metal Plate Cutter Machine)

FRIM (Forest Research Institute of Malaysia)

GA (General Assemble)

GPTM (Grinder Power Tool Machine)

H2O (Water)

HAMP (Hot Air Moulding Template)

IAM (Inventor Assembly)

IPT (Inventor Parts)

LCA (Life Cycle Assessment)

LMP (Lean Manufacturing Process)

MARDI (Malaysian Agricultural Research and Development Institute)

MDF (Medium Density Fibreboard)

MDB (Metal Work Drill Bit)

xxv

MFA (Material Flow Analysis)
MUF (Melamine Urea Formaldehyde)
MSP (Mild Steel Plate)
MTIB (Malaysian Timber Industry Board)
NaCl (Sodium Chloride)
NaClO (Sodium Hypochlorite)
NaOH (Sodium Hydroxide)
PALF (Pineapple Leaf Fibre)
PLA (Polylactic Acid)
PP (Polypropylene)
PVA (Polyvinyl Alcohol)
RAM (Random Access Memory)
RTM (Resin Transfer Model)
RoSD (Rules of Sustainable Design)
SEM Scanning Electron Microscope
SME (Small Medium Micro Enterprise)
UI (User Interface)
UTM (Universiti Teknologi Malaysia)
UiTM (Universiti Teknologi Mara)
VV (Verification and Validation)

xxvi

CHAPTER ONE
INTRODUCTION

1.1 BACKGROUND OF STUDY

Sugarcane is a rapid growing plant usually grows near water for example
pond, and drain. More than 45% of sugarcane bagasse and pith (BP) creates a problem
in disposal after being crushed by the hawkers for its juice. Sugarcane juice is
commonly sold by a hawker in Malaysia especially in night markets and roadside
stalls as described by the researcher “several collections in Cheras night markets had
conducted on bagasse juice” (Leang & Saw, 2011). The outer layer of sugarcane Pith
can be peeled off using a peeler knife tool and for Bagasse it can be crushed using
sugarcane crush machine that enables for this components turned into raw biowaste.

Referring to James (2007), this waste BP sugarcane had potential exchange
into biodegradable waste material and he had used Life Cycle Assessment (LCA)
through his experiment by analysing these three components. As highlighted (De
Souza et al., 2015) this green plant contain “sucrose”, “lactose”, “fructose” and
another component that can be treated with the chemical.

Based on Malaysian Agricultural Research and Development (MARDI) they
believe, “Malaysia has 146 genetic cloned canes, used by a hawker in different states
and used in mass biocomposite production” (S.LTan, 1989).

This is also cited in Robeson (2014), “ a none copolymer chemical natural
treated substance capable used as a component to loose “lignin” and the
measurement mixing adhesive is important in manufacturing natural biocomposite”
(Robeson, 2014). Review by these four scholars, the measurement weight used for
manufacturing BP biocomposite it is important to analysed and recorded referring in
LCA through manufacturing for household product design application.

As explain by Wong (2007) stated in Conference on the Malaysian Economy:
Development and Challenges “a rapid growth green plant in Malaysia can improving
and gaining in economically on the material is reusable takes as a material action
into waste bio-product”, (Wong, 2007). As stated through this research, this rapid

1

growth waste raw material such as “saccharum officinarum” (yellow cane) can help
in improving economic impact in transforming into a household product design
application.

1.2 MANUFACTURING IN BIOCOMPOSITE PRODUCTION

The other bio-source that is useful in manufacturing are for examples jute,
ramie, sisal, coconut husk, banana fibres, flax, hemp, cotton, palm oil and pineapple.
Another approach in designing household craft product application mentioned by
Seow et al., (2016) is a mass production using LCA as a manufacturing process to
minimize energy consumption in mass production. In industry, an example is the
Bagasse Flax Chair, which was made by using two items that are Bagasse and Flax
(BF).

The ingredients were mixed combining two main items to create a single chair.
Another chemical called “Polylactic Acid” (PLA) is added into the mix and melts at a
high melting point to turn the mix into the resin, which is twice as much faster to
harden. The bonding had been used by Allen (2016) such as “Polyvinyl Alcohol”
(PVA) which is an adhesive agent to help BP biocomposite to bind together and
compressed to cure by using hot air moulding press to become a household craft
product application based on the moulding design.

Meanwhile, Rodrigues (2016) had set up a compress mould design allowing it
to compress BP by mixing these two components that can reduce the disposal of BP
and suitable for use in household craft product application and capable in increasing
productivity and are economical.

In manufacturing BP biocomposite, Sugarcane was studied by N. L. Li-
An’Amie (2015), in designing sugarcane basket as the characteristic of BP composite
available is naturally bio absorbent and moreover, sugarcane is not flexible making it
good to be applied as acoustic sound absorption. In the manufacturing process of BP
biocomposite the drying process is very important so that during production or design
of the certain product for example particleboard, usage of this substance can reduce
utilization of recycle bin for disposal.

Malaysia was using bagasse as waste material since 2010-2013, in
biocomposite particleboard manufacturing industry that had increased from 303,000

2

tons to 500,000 tons, giving a good impact on expanding Malaysian economy by
selling bagasse particleboard for use in wall panel manufacturing. Moreover, some of
the statistic expressed in figure 1.2.1 showing Malaysia’s solid waste management
department in the domestic area that “bagasse throwing largest waste component (at)
more than 500,000 tons per day” (M. H.I.M. Junoh, n.d).

Figure 1.2.1: A Diagram of Domestic Solid Waste Statistics (Department of Solid Waste
Management), 2013, (M. H.I.M. Junoh, 2014)

Malaysia strives to use sugarcane bagasse as a potential product industry and
another sort of product. Therefore, it had an opportunity in manufacturing BP
biocomposites for product application to test on bagasse strength instead of disposing
it and using PVA as the bonding agent in manufacturing BP biocomposite household
product.

1.3 POTENTIAL OF SUGARCANE

Chait (2014); S. Moreno (2013); Paul (2011), these three scholars review on
the potential of waste sugarcane bagasse have been focusing on several industries such
as bottle packaging, food packaging, textiles, paper, animal feeds, and biocomposite
board.

This green plant as it mentions from Aminudin et al., (2017) from Department
of Structures and Material, Universiti Teknologi Malaysia (UTM) cited through Sun,
Sun, Sun, & Su (2004) in Journal Carbohydrate Polymers. They stated, “Malaysia had
disposed of 1 ton this green plant per generally 280 kg Bagasse and Pith have used
for per product design application and 54 million ton bags of these components have
annually used in other application, examples ceiling panelling and partition board”,
(Sun et al., 2004).

As it understands in this statement above, sugarcane is a rapid growth green
plant and has a category as it is waste bio green source for both components BP, and
besides, it is renewable, low cost and low-density fibre it can use in the product design
application.

3

Other green plants example Banana, Paddy, Grass, Ramie, Aflax (Bast Fibre),
Flax, Jute, Nettle, Cotton and Abaca these green plants have a review in a book of
Industrial Application of Natural Fibre referring to Ussig (2010). He reviews these
natural fibres can use in designing and manufacturing in tarpaulin geotextile, bags and
carpets.

It also supported in Journal Advances in Polymers Technology, “recently,
these fibres widely used in the conventional manufacturing process over years and
also, availability of this natural bio source, this is because it is used as an application
in semi composite production”, (Saheb & Jog, 2015).

As it stated both researchers, these green plants listed it has used commonly in
manufacturing process especially in fabricated, knotted net, knitted good, wadding,
fleece and felt. Besides, sugarcane is also part of rapid green plant capable use as a
potential material in product design application through development on using Hot Air
as the main technique for the manufacturing process.

1.4 THE CONTEXT IN HOUSEHOLD PRODUCT APPLICATION AND
PRODUCT IN BIOCOMPOSITE

LCA framework has three roles that are in environmental, social, and
economic use for manufacturing design process and helping on the design process
especially in BP biocomposite. In figure 1.4.1, LCA framework has in context the
product by M.Rosen & Kishawy (2012), disposal of BP biocomposite waste sugarcane
can gain profit on the economy.

Figure 1.4.1: LCA Framework Centralize on Manufacturing Process, (M.Rosen & Kishawy,
2012)

In this context, the product for biocomposite had helped on the mass
manufacturing process, for example using biocomposite based on palm oil plant;
besides BP biocomposite had become popular because of wide availability and
plentiful in Malaysia. Palm oil composite had its own potential research according to

4

S. S. Suhaily, Jawaid, Abdul Khalil, & Ibrahim (2012); Sciencelab.com, (2018), this is
because of its durability, strength and bio biodegradable properties leading to further
recycling it to be used in manufacturing of product by using PVA in APPENDIX JB
p.241.

The other example of natural Biocomposite uses is in plastic mass production,
in which using other polymers such as “Polypropylene” (PP) and “Polylactic Acid”
(PLA) for product manufacturing for example toys and a shopping bag that are easy to
recycle. It was indicated in a study by Rydz, Sikorska, Kyulavska, & Christova (2015)
that some of the polyester biocomposite uses are in the manufacturing process in
referring to LCA mass production.

In a book title Agricultural Biomass-Based Potential Material, for the product
design towards of development on material and manufacturing process has started by
Mansor, Salt, Zainudin, Aziz, & Ariff (2015, p. 121-141). They understand towards
on potential material used in a product design application, “beside growth in using
synthetic fibres in polymers composite, another group is a natural biocomposite from
natural fibre based from biodegradable source or waste component and it accordingly
used in household application”, (Mansor et al., 2015).

In a Handbook of Recycling State of the Art for Practitioners, Analysts and
Scientists in the statement above are relevant inside on this book written Allwood
(2014, p. 445-477). He believes, “if the waste natural biomaterial cannot be recycled
properly it could be down cycle as a disposal natural fibre component into
development example composted or incinerated for energy generation”, (Allwood,
2014).

Referring on this two citation above, Kaspar & Vielhaber (2018) had
combined these scholars understood towards design thinking, in combining science,
design, and manufacturing process lead into 50% by 50% on the systematic design
approach. In other words, it combines traditional technique in the manufacturing
process with modern low-cost technology use such as Hot Air and it is improved
material optimized design and designs it for product design application.

1.5 PROCESSING THE BAGASSE AND PITH (BP) BIOCOMPOSITE

Pallavi, Elakkiya, Tennety, & Devi (2012) study regarding analysed sugarcane
contains and found a high amount of enzymes such as “phenolic” inside this green

5

plant. Next, Cesarino, Araújo, Domingues Júnior, & Mazzafera (2012), all agree to
this problem statement which is “phenolic” compound covering by “Cell Wall” is
high in “lignin” contain and this is because it helps “Vascular Bundle” to improvise
on the strength of the chain structure such as “p-coumaryl alcohol”, “sinapyl alcohol”
and “coniferyl alcohol” in “saccharum officinarum” structure, as per figure 1.5.1.

Figure 1.5.1: An Overview of Sugarcane “saccharum officinarum” Structure via Containing
“lignin” in A “Cell Wall”, (Cesarino et al., 2012)

In Journal of Plant Psychology Bottcher et al., (2013) had cited through
Annual Review of Plant Biology and Biosource Technology refer from Carroll &
Somerville (2009); Rabelo, Carrere, Maciel Filho, & Costa (2011), “Bagasse is the
inner layer part and Pith are the outer layer part. Moreover, it is covered by
“Vascular Bundle” and “phenolic” compound such as “lignin”, “hemicellulose”,
and “cellulose”, that are able to produce” bioethanol”, (Carroll & Somerville, 2009;
Rabelo et al., 2011).

From the statement above they analysed the problem with high content
through this chain in green plant contain “lignin” is 23%, “cellulose” 39% and 25%
of “hemicellulose.” By referring in New Phytologist, wrote from Marriott, Gómez, &
McQueen-Mason (2015, p. 1366-1381), these three components the “lignin” is the
main problem for BP which it can cause burning while it stayed inside Oven Drying
Machine and it is also prevented adhesive agent to bond during the manufacturing
process.

Through this problem stated above, “lignin” content in BP sugarcane it is
main problem and researcher will be a review on an experiment to loose “lignin” and
detail on the manufacturing process in fabricating BP biocomposite in (The Basic
Skill in Manufacturing Processing using Natural Biocomposite) p.48.

1.6 PROBLEM STATEMENT

I. Base on the background of study it giving a good statement high disposal
amount of sugarcane bagasse and pith at night market

6

The preparation of BP composite, as the main ingredient in the manufacturing
process this is because a review from Resource Conservation and Recycling wrote by
Moh & Abd Manaf (2014, p. 50-61). They state “the disposal of raw BP sugarcane
has increased from 16,200 tons in 2001 to 19,100 tons per day since in 2005 and
about 0.8 Kilogram (Kg) per day collected at night market”, Moh & Abd Manaf
(2014).

Practitioner or a manufacturer which is using sugarcane Bagasse and Pith are
unpopular for mass production, but more towards juice and raw sugar production. As
it stated in International Journal of Advanced Scientific and Technical Research,
“Malaysia used sugarcane more than 70% and are highly used in the food industry”,
(Tagare, Patil, Talaskar, & Wadar, 2013, p. 70). Through on this significant, this large
waste raw material from sugarcane plant able to achieving in keep providing particle
board and moreover, it also can be processed into BP biocomposite.

II. Base on background study had stated hard to bonding when high in
“lignin” contain in BP biocomposite
Most of the young and mature plants contain their own “Xylem” and it is the

reason why “lignin” will be hard to bond during experiment Schadel, Blochl, Richter,
& Hoch (2009). Therefore, the BP properties cannot be bonded together because of
the presence of “lignin” and this will lower the strength properties. It supported by
Brienzo, (2016, p. 156-188); Carvalho, (2015), both of these researchers had a study
on sugarcane “lignin” properties.

This complex structure contains other “polymer” example “hemicellulose”,
“cellulose”, “sinapyl alcohol” and “p-coumaryl alcohol”. Furthermore, it is as chain
structures, which helps this “vascular” plant to survive in producing sugar.

In sugarcane plant studied by Hoang et al., (2017), they have analysed on the
properties content of this plant “polymer” such as, “lignin” 18% to 22% and 23% of
“sucrose”. Furthermore, review from Hemmilä, Adamopoulos, Karlsson, & Kumar,
(2017), this “lignin” it also protected by “Cell Wall” that prevented from dense
domestic chemical adhesive or regular glue solution to bond it with other natural fibre.
Moreover, they had reviewed these active natural “polymer” can generate burned
when it dried under high temperature via using Oven Drying Machine or microwave.

The properties of BP as stated by Lahr, Junior, & Fiorelli (2015), for
manufacturing are after module of rupture (MOR), a module of elastic (MOE) and

7

Thickness Swelling (TS) tests and is suitable for use as biocomposite for furniture
after “lignin” is reduced.

1.7 RESEARCH OBJECTIVE

Base on the problem above the objective is:
I. To identify product application that suitable use for Bagasse and Pith
(BP) biocomposite
BP Biocomposite can give huge positive impact if used in food packaging,

household product application, and medical application according to Dungani et al.,
(2016), and because of properties its suitable use is; household product design
application.

II. To reduce the amount of “lignin” content in BP biocomposite using the
boiling method and “Sodium Chloride” (NaCl) as a treatment experiment
Anukam, Mamphweli, Reddy, Meyer, & Okoh, (2016) these researcher

understand, the “lignin” is a one of component that contain inside of this sugarcane
enable for this “vascular” plant to produce sugar and other similar “polymer” chain
structure such as “lactose” and “fructose”. Besides they had reviewed, these natural
“polymer”, it is also prevented from adhesive to be bond and it generates burned
when stayed too long inside high-temperature oven dried machine.

The experiment on sugarcane “The use of high content boiling temperature to
sugarcane it reduced “lignin” content and using it turned into cloudy water surface”
(Cortez & Gomez, (1998); Ou et al., (2007).

In a Journal of Biological & Environment Science stated on Rohanipoor,
Norouzi, Moezzi, & Hassibi (2013, p. 77) cited from Savvas et al., (2007) and
understand both researchers Beukes (2007, p. 111), and Chaudhary (2010, p. 45). A
proper amount of weight using “Sodium Chloride” (NaCl) capable to treat this
organic polymer.

Insignificant, another way on using the same experiment by using the
induction stove, gas cooker, NaCl or in manual way flaming charcoal are suit to this
situation and these can maintain the properties of BP biocomposite. Based on the
above experiments, the researcher will be followed by Chaudhary (2010); Chompu-

8

inwai, Jaimjit, & Premsuriyanunt (2015); Chowdhury et al., (2015); Jokar &
O’Halloran (2013), as toward of treatment and manufacturing of BP biocomposite.

III. To use Hand Lay Up Technic and Hot Air Moulding Template (HAMP)
as a tool for fabricating BP biocomposite block
A low technic such as vacuum forming, spray up and filament winding

technique researched by Zin et al., (2016) had presented their paper at IOP Conference
Series; Material and Science. Through their study, hand lay-up technic it is a
development manufacturing process for fabricating natural biocomposite.

Beside of these techniques, according to this researcher, “a development on
previously existing technologies such as hot press, cool press and injection moulding
it can develop into low technology manufacturing process such as hot air” (Tripathy,
2009). A low technology manufacturing process such as cool press, hot press and
injection moulding capable to develop into similar technique such as using Hot Air
Moulding Template (HAMP).

Through this research, similar low techniques such as hand lay-up technic,
vacuum forming, spray, or cool press had categories as a low technology
manufacturing process in fabricating BP biocomposite block. On the other hand, using
hot air technology such as Ceramic Kiln Chamber or Oven Dried Machine capable to
cure this BP biocomposite block.

1.8 CONTEXT AND SCOPE OF RESEARCH

1.8.1 Context

The context of this study is to focus on, two-components of Bagasse and Pith
biocomposite properties and the adhesive, to analyse properties strength after
processing and the manufacturing process of BP biocomposite household product
design by using Hot Air Moulding Template (HAMP). In addition, these experiment
and manufacturing process will be guided along with the LCA framework as a
guideline for the designing in household product application.

9

1.8.2 Significant of Study

The sugarcane Bagasse and Pith (BP) are used in several biocomposite mass
production, for example, particleboard and geotextile. These are important towards the
society and sociology as to improve the manufacturing process and to reduce forest
plant usage as advocated by Forest Research Institute of Malaysia (FRIM) and
Malaysian Timber Industry Board (MTIB) who are trying to preserve Malaysia plant.

Besides, the low technology manufacturing process had analysed LCA
framework to improve the manufacturing process by Almeida, Agostinho, Giannetti,
& Huisingh (2015), as a promotion to local production especially applied in BP
composites product manufacturing.

Based on this research from Drzal, Mohanty, & Misra, (2001), had studied on
low technique manufacturing on open mould concept and besides, designing on mould
such as HAMP are classify as low technology manufacturing process. It supported
from Nicosia, (2005) based on his article review, using a proper flat surface or block it
enable for this abundant waste natural fibre to manufacture and used it as a product
design application.

Other potential design had studied from Baghaei, (2015) on low technology
manufacturing process and it, have a right way on designing by using hand lay-up
technic as a fabrication technique example in product design application or ceramic
design application. Furthermore, a waste material it is part of the design process that
capable to develop this waste raw material such as BP from sugarcane, HAMP mould,
and finally with the design based on experiment towards the potential of the product
design application.

It is applicable for manufacturing process on building construction by using
BP composite board by Madurwar, Ralegaonkar, & Mandavgane (2013) to be used in
improving thermomechanical behaviour and it is a material as well as environmentally
eco- friendly.

The use of BP composite board is gaining popularity in Malaysia. Moreover,
an entrepreneur is more adept in BP composite usage they are able to produce a good
quality product based on LCA framework, as analysed by Hassan, Yaacob, &
Abdullatiff (2014). These prove to be economically and have a good impact. An
example is the use of sugarcane as “bioethanol” fuel for a car by Simas-Rodrigues et

10

al., (2015), in Brazil that proves given an opportunity, sugarcane can be used as oil
source as well.

1.9 AIMS AND RESEARCH QUESTION

1.9.1 Aims

The aims of this research project are to identify manufacturing process on BP
biocomposite for household product design application using Hot Air Moulding Press
Template (HAMP) or by the hot press as the technique for a manufacturing process.
These processes are carried out using several machine, apparatus, and equipment
following a set of an important guideline in the manufacturing process.

1.9.2 Research Question

The projects are cover on experiment and laboratory procedures are:
I. What are sort techniques to increase mass production BP biocomposites
for product application especially for low technology?
Using a hand lay-up technic and wire mesh aids BP biocomposite concentrate

cure the adhesive. Some example uses wire mesh as a wall panel construction to
prevent stiffness. It also bound together as part of architecture construction giving the
strength “in term of flexibility, wire mesh also can strengthen up construction”,
(Ahmad Mousa, 2014).

This allows usage in the household product design application as to clamp
together alongside with bagasse and pith to cure. Meanwhile, Ahmad Mousa (2014),
also add a fastening tool comprising of Bolt and Nut to fasten up the wire mesh
framing, and immediately it adds rigidity to the concrete construction. Thus, this
application allows improvement on the strength and concentrate on compression and
curing to form the product.

II. How to decrease “lignin” contains “saccharum officinarum” (yellow cane)
Bagasse and Pith (BP) biocomposite?

11

The formula formulized by Abdel-Halim (2014), used two different agents for
examples “Sodium Chloride” (NaCl) resulting “the study shows that using a good
timing the best result will significate the product, good condition literalize to lignin”
(Abdel-Halim, 2014). Therefore, the “lignin” from yellow cane can be lost slowly,
and immediately the product exaggerated into its original condition.

12

CHAPTER TWO
LITERATURE REVIEW

2.1 OVERVIEW OF MAIN RULES OF THE LEAN MANUFACTURING
PROCESS

The overviews of this literature are part of criteria before entering the LCA
framework via through mass production via lean manufacturing product application.
Moreover, these search regarding on how the manufacturer, practitioner, and
researchers level design thinking to conduct a laboratory experiment via using waste
material such as yellow cane via manufacturing product application.

Through this course, as designers the main rules of the lean manufacturing
process such as determine the potential of green development low technology that is
able to increase through Element of Sustainable Design (EoSD) such as the potential
of waste material, good added value design, and able to increase of economic impact.

Therefore, to increase manufacturing process, designers need to equip with
knowledge such as echo centric, techno-centric and socio-centric as key point via
mass manufacturing for product application through Design for Sustainable (DfS).
Moreover, Design for Environment (DfE), designer able to enhance via the
development of low technology manufacturing process through experiment via in
LCA as Slow Design experiment through manufacturing product application.

As conclusion toward the End of Life (EoF), on this manufacturing process,
practitioner and manufacturer able used this framework to gain an economic prospect.
Besides, it helped to improve the manufacturing process for helping especially for the
rural area small industries and gaining their profit marketability on towards of product
design application.

2.1.1 The Rules of Sustainable Green Product Designer towards Mass
Manufacturing Design

The Rule of Sustainable (RoSD) to achieve mass manufacturing review by L.
Hu et al., (2017); Leite & Vieira (2015), had understood that mass production lean

13

manufacturing framework and the increase of demand process can maximise potential
in low technology development that is able to reduce 25% the energy consumption.
Meanwhile the other paper from Pedgley (2009), D&B is the emerging in demanding
development for the mass manufacturing process and thus, the designer can develop
low technology in improving material, for example, BP biocomposite.

D&B framework journal by Mueller & Thoring (2012), there is an
understanding of the combination of design thinking and lean manufacturing mass
production. In this line, mass manufacturing for designer needs to look with the
previous review with the other conceptual framework and give the benefit towards
D&B development in low technology.

May, Stahl, Taisch, & Kiritsis (2016), had classified D&B framework for LCA
for the mass manufacturing process and according to RoSD, the designer needs to
include example paradigm on low technology design development, tools or
methodology and how the process will be done in figure 2.1.1.1. These D&B
framework criteria help the designer to understand the development and planning for
designing BP biocomposite for product household product design application.

Figure 2.1.1.1: The D&B Design Criteria Framework for Life Cycle Assessment Framework
(LCA) via Mass Manufacturing, (May et al., 2016)

S. Li, Kattner, & Campbell, 2017, believe designer that used LCA via D&B
framework for mass manufacturing BP biocomposite for household product design
application can compile several results. According to her “designer can conduct a
quantitative LCA framework as the evidence of experiment process as an element of
the design process and this can strengthen up evidence as to the proof of
manufacturing process” (S. Li et al., 2017).

The other journal was written by Rodríguez-Olalla & Avilés-Palacios, 2017,
agree with the manufacturing process of BP biocomposite from natural waste material
and also agree for a designer to do the development on low technology towards mass
production of household product design application. Furthermore, D&B for RoSD are
defined by three criteria for manufacturing example that is flexible, and time that can
give a good green quality via mass manufacturing process, see figure 2.1.1.2.

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Figure 2.1.1. 2: The Direction D&B Trend Criteria Framework For Mass Development Mass
Production For Furniture Component, (Chen et al., 2015)

Li, Gomez, & Pehlken, 2015, a study on design mass manufacturing, in LCA
framework criterion via mass production and classified into three sections that are
material selection, product application, and low technology development. According
to her “as a practitioner need to acquire this three perspective as to achive level of
technical thinking and are called as a conscious individual mindset” (Z. Li et al.,
2015). Boetker et al., 2016, had classified three RoSD via mass manufacturing
framework see figure 2.1.1.3.

Figure 2.1.1.3: The Three Section Framework via Green Mass Manufacturing for Industry
Design, (Boetker et al., 2016)

He had included three domains for mass manufacturing that designers need to
including, three section examples are simple geometry form design, process
manufacturing tools and finally the performance of the product. According to him
“this mass manufacturing framework through D&B development process needs to
move concurrently as the rules and it will not waste time for production line”
(Boetker et al., 2016). Moreover, it had contained an element of design in D&B
framework as the guideline for a designer to study on the development of low
technology for BP biocomposite household product design application.

In conclusion, Rules of Sustainable Design (RoSD) have defined three criteria
for manufacturing, flexibility and time. Moreover, the performances towards
technique manufacturing for mass production application are simple geometry formed
design, process manufacturing tools and finally the performance of the product.
Therefore, the main requirement of the manufacturing process covering these three

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domains is covered waste material BP biocomposite, manufacturing process and types
of product application.

2.1.2 The Element of Sustainable Design (EoSD) via Mass Manufacturing
Process for Industry Design

The Element of Sustainable Design (EoSD) in mass manufacturing design that
researcher needs to equip are three elements via Ford & Despeisse (2016) such as
waste raw material, extended product life and configured value chain.

These three configuration towards manufacturing process example in
producing BP biocomposite and according to him, “these three additional
manufacturing help designer to achieve the value of disposal material, furthermore it
had potential to be used for mass manufacturing, and these three elements as the
guidance for low technology development” (Ford & Despeisse, 2016).

Bocken, Short, Rana, & Evans (2014), agree with these elements on the value
potential of waste material, good added value design, and economic added value gain.
Moreover, they had been in use for every manufacturing product application using
waste raw material as a focal point towards of manufacturing process see figure
2.1.2.1.

Figure 2.1.2.1: The Element of Sustainable Design via Mass Manufacturing Process for
Industry Design, (Bocken et al., 2014)

These two scholars agree with the three elements design and believe these
elements of design can also help the designer to generate the idea of the development
of D&B low technology for manufacturing from BP biocomposite for household
product design application.

This framework study by Kohtala & Hyysalo (2015), have helped the
researcher in preparation for a mass manufacturing process using natural waste
material Bagasse and Pith (BP) biocomposite. There had stated, “a low technology

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development gives a good impact for improving the manufacturing process and thus
help the designer to sustain existing material from waste towards demand via mass
manufacturing” (Kohtala & Hyysalo, 2015). Besides, they have studied in improving
D&B low technology to give a benefit for manufacturing engineer and improving 21%
to 35% in low technology demand manufacturing process.

Next, Friedman (2003), had agreed via EoSD as the platform for
manufacturing and he had the idea of evolution or development in D&B low
technology giving a new meaning for industrial design to move forward for the mass
manufacturing process. Kelley (2015) had minimized EoSD framework to make
comprehensive and stand forward for a designer to develop their design through mass
production of BP biocomposite for household product design application.

These three elements consisting of Desirable, Feasible, and Viable had
delivered for a designer to move forward for development design for mass production,
see figure 2.1.2.2.

Figure 2.1.2.2: The Variable Design Framework via the Development of Sustainable Design
Process for Industry Design Manufacturing, (Kelley, 2015)

These EoSD frameworks have potential in helping the designer to recognise
potential design work and arrange planning work in design for mass production and it
had been reviewed by Farhana & Bimenyimana (2015). Additionally, this design
workflow supported by their idea as she believes, “during this phase designer need
recognize on existing low technology that provides low cost and fast growth for mass
production” (Farhana & Bimenyimana, 2015).

With these beliefs, the researcher can bring into development D&B low
technology, where the drawing and sketching helped by EoSD as the guideline to
generate more experiment and thus bringing a lot of possibility via existing low
technology that can develop into a manufacturing process.

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In conclusion, for craft household product design application from BP
biocomposite, the designer is able to design and manufacture via the development of
low technology to improve LCA framework. This understanding is what a designer
must study through EoSD Framework that is delivered into four categories such as,
waste material selection, development of D&B low technology, manufacturing
process and material properties experiment.

Thus, the designer can generate more idea into detailing via D&B low
technology development and increase the value of quality material as a scope of mass
production that delivers the green design.

2.1.3 The Design for Sustainable (DFS) via Product Design using Waste BP
Biocomposite

The movement via Design for Sustainable (DfS) material by using BP
biocomposite material from yellow cane consists three Design & Build (D&B)
development movement as studied by Penglinton Roger (2010), such as Eco-Centric,
Techno-Centric and Socio Centric.

These three levels of design thinking are reflected by, Humphries-Smith
(2008) had the potential for use in designing curriculum design process and this
guideline design via her idea had the potential for use in designing BP biocomposite
craft household product design application using BP biocomposite waste material
from “saccharum officinarum”( yellow cane).

The design movement for DfS is a basic design principle for examples learnt
from nature, or design is art and never be science that is the terminology in green
design and this belief by Buss (1988), moreover, the BP biocomposite material can
move forward into new development design.

Throughout DfS framework for designing a household craft product
application as a product application by Lindow, Woll, & Stark (2012) via
development on craft household product application and this gave an opportunity for a
designer to develop the design, see figure 2.1.3.1.

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Figure 2.1.3.1: The Basic Guideline of Technology Development via Element of Sustainable
Design (EoSD) for Mass Manufacturing Design, (Nieuwenhuis & Katsifou, 2015)
A study by David Klein (2011), a traditional design method is a path of

development D&B process in industry design via LCA framework that became a basic
design form and this belief from his research can improve on the quality of reducing
material use.

Additionally, Cradle to Cradle framework and LCA framework also had been
studied by Vishal Yashwant Bhise (2014), according to him “a biocomposite material
by using Cradle to Cradle for designing product application is starting with raw
material and this is not similar to the DfS flow design process which is starting with
design” (Vishal Yashwant Bhise, 2014). The two approaches had an argument in the
DfS framework and these gave a good picture of a different starting point for the
design process.

Next, this conceptual design movement in DfS for material processing by
using BP biocomposite material it consists of three D&B development movement
study by Penglinton Roger, 2010 such as Eco-Centric, Techno-Centric and Socio
Centric. These three level parameter of design thinking are reflected by, Humphries-
Smith (2008) had the potential for use in designing curriculum and this is shown in
figure 2.1.3.2, the guideline design flow chart process had potential use in designing
BP biocomposite household product application.

These beliefs in the three-dimensional design workflow in designing
household product design application BP biocomposite for product application had a
connection with the LCA framework, which is by using these three separate variables.

Figure 2.1.3.2: Parameter Process of Design for Sustainable (DfS), (Humphries-Smith, 2008)

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This level of design thinking for DfS studied by Mazé & Redström (2007), an
Eco-Centric is a value of design knowledge that leads into system production as a
challenge of the design development and this good potential is used as the market
value.

In exploring DfS design thinking via Techno-Centric had also been defined by
Carlgren, Elmquist, & Rauth (2014) “the relation of design development is mindset
towards end of design by using experimental innovation design that can pass as a
concept and this gives a chance for another sector to use it as a guideline in the
manufacturing process”(Carlgren et al., 2014).

Some example had used this framework by designing product application
using Cradle to Cradle for biocomposite material by Andrews (2016). He had
designed home household product design application component and it also uses two
combinations, which are Eco Centric and Techno-Centric to apply this design.

Through these understanding, D&B designers need to predict what kind of
product output will be formed either Eco-Centric, Techno-Centric or both, before
starting to sketch or using Computer Aided Design (CAD) modelling tools to design
Bagasse and Pith (BP) biocomposite for product application.

In conclusion, DfS is one of the design processes for the researcher to analyse
a potential for technique and low technology that will be applied to the manufacturing
process for household product design application. Furthermore, these may improve
D&B and DfE to translate into an existing technique that may be able to develop and
enter the manufacturing process in product application.

2.1.4 The Designing for Environment (DfE) Towards Product Design

Design for Environmental (DfE) framework, has the potential to be used for
manufacturing design process and this research report by Cramern (1997), through her
previous study via D&B low technology development. Moreover, according to her,
“design for environment (DfE) had potential use through technology development in
DfS evolution framework and this gives bonus by reducing material waste”,
(Cramern, 1997).

The DfE frameworks research by Fitzgerald, Herrmann, Sandborn, Schmidt, &
Gogoll (2007), agree that this framework gave benefit to LCA and it can enhance

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mass manufacturing BP biocomposite for household product design application after
researcher make a decision on DfS design through D&B low technology development.

Research related to DfE via Rosen & Kishawy (2012), is in optimizing the
performance design process and give benefit through productivity value to sustain BP
biocomposite waste for the future market. The DfS earlier stages, research by
Peruzzini, Raffaeli, & Mandolini (2017), defined design development are by referring
designer sketches or mock-up and it helps DfE to analyse the detailing of the product
by using 3D CAD geometric modelling tools.

Some examples use DfE by Kembaren, Simatupang, Larso, & Wiyancoko
(2014), to product development manufacturing process in Cradle to Cradle designing
low technology that has a meaning as a conceptual design process which is related
with Slow Design concept.

These scholars had claimed each framework to have a connection between
DfS, DfE, and LCA through D&B low technology development that helps produce
meaningful product especially for manufacturing BP biocomposite household product
design application from “saccharum officinarum”, see figure 2.1.4.1.

Figure 2.1.4.1: The Key concept of Product Design Process with combination DfS and DfE to
Evaluate, (Nutassey, 2014)

Through Slow Design concept via DfS gave the understanding on the design
process as the outline for manufacturing process by Nutassey, (2014) and thus, help
design the critical thinking on how to sustain BP biocomposite with the existing low
technology application through DfE. Additionally, this idea agrees with Haemmerle,
Shekar, & Walker (2012), in DfE giving the potential for Cradle to Cradle involving
with the design process especially for manufacturing BP biocomposite from yellow
cane for household product design application.

According to him, “the awareness of waste material for design process LCA,
gave benefit to sustain DfS to develop into potential product application and this gave
rewards through Cradle to Cradle performed” (Haemmerle et al., 2012). The two
scholars are agreeing with the design process via DfS and DfE that can perform LCA

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to create product via BP biocomposite craft household product design application by
using the existing low technology.

The DfE requirement as tools to evaluate designer sketches, mock-up, or 3D
modelling tools in analysing the potential of DfS and D&B had been studied by
Bernstein, Ramanujan, Zhao, Ramani, & Cox (2012). Based on their understanding,
“the DfE are required to combine with the DfS, D&B to perform evaluation
throughout design critics via factual knowledge and this enhance the quality of the
material produced through LCA” (Bernstein et al., 2012).

Wilkinson & De Angeli (2014), Slow Designs in DfS design framework are
the key concept for a designer to evaluate several experiments and these can enhance
the User Interface (UI) via LCA for BP biocomposite household product design
application.

Finally, Tung, 2012 understand D&B, DfS, DfE, and LCA have the potential
for use in Cradle to Cradle for designing biocomposite material component such as
household product design application, see figure 2.1.4.2. Moreover, they declare a
statement “as a designer it is important to understand the chain value of D&B, DfS
and DfE as a decision before entering LCA via designing product application as the
important part in the availability of green material”, (Boks & Komoto, 2007).

Figure 2.1.4.2: Natural Biocomposite Manufacturing Process using Low Technology for Craft
in Product Application, (Tung, 2012)

These scholars understand in D&B, DfS, DfE and LCA helping to reduce
material waste, for example, BP biocomposite material, have potential in designing a
craft household product application and called it Slow Design experiment.

The conclusion for the DfE framework is part of the design framework, which
is combining with D&B and DfS. Thus, these allow the researcher to develop a
manufacturing process for the product application and furthermore, it derives for LCA
(Life Cycle Assessment) as an application for a manufacturing process using Bagasse
and Pith (BP) biocomposite material.

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