Zhang & Rai (2016) have their own different opinion, even the technique is
different in low technology manufacturing process or high technology manufacturing
process, and for researchers to test even if it involves with craftwork method” (B.
Zhang & Rai, 2016).
Through, these two researchers believe craftwork technique such as using
HAMP mould and waste BP component for manufacturing craft household product
application makes it important for the researcher to conduct two tests such as flexure
test (FT) and water absorption (WA), see figure 2.3.9.6 and figure 2.3.9.7.
Figure 2.3.9.6: 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)
Figure 2.3.9. 7: An Example Sample of Water Absorption (WA) Test Effect for Cotton
Natural Biocomposite, (G. Huang & Sun, 2007)
Next, H. Deng et al., (2010); Toh Wen Yee, Lai Jau Choy, & Wan Aizan Wan
Abdul Rahman (2011) these researchers experiments on another natural fibre for small
scales craftwork industry such as Flax fibre and Sago Pith. Using PVA solution as the
adhesive mixture for these natural fibres is recommended and they suggest BP
biocomposite that uses the same properties is capable of use in craft household
product design application.
However, the researcher can test the potential of this natural fibre before the
design process and based on the result, the researcher can use the data experiment as
proof of the design for product application.
Another example of Slow Design experiment and test study by Fiorelli et al.,
(2012), a standard water absorption (WA) test for natural fibre particleboard is 24
hours and the test for the flexure depend on how many newtons can be applied until
crush based on ASTM D 1037.
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Queensland, Bullen, Pty, & Queensland (2015), studied the material properties
strength such as PVA and BP biocomposite. They suggest these two components are
not suitable for use in heavy industries and this is because of the amount of newton
force permissible are low restricting its use to craft household product only.
Through these scholars believe, the calculation is very important to analyse the
potential of PVA adhesive and the natural fibre. The test conducted in the experiment
is based upon scholar’s study, only two tests that are suitably used for low technology
manufacturing processes such as flexure test and water absorption.
2.4 OVERVIEW OF DESIGN PROCESS FOR CRAFT HOUSEHOLD
PRODUCT APPLICATION BY USING HOT AIR MOULDING
TEMPLATE (HAMP) AS LOW TECHNOLOGY MASS
MANUFACTURING PROCESS
The overview of this research is based on the design process for manufacturing
craft household product design application and additionally, using Hot Air Moulding
Template (HAMP) as a mould applied for low technology mass manufacturing
process for craft industries. Secondly, the researcher reviews the existing technique
for low technology manufacturing that is used in small scale industries and
furthermore, it is similar to the development manufacturing process using HAMP.
Next, the researcher will be studied on the benefit and importance of the
development of the technique. Moreover, it encourages rural industries to understand
the importance of waste components such as BP “saccharum officinarum” (yellow
cane) and other natural fibre used.
Thirdly, this overview will cover design process such as sketches, and 3D
modelling using Autodesk Inventor to design prototype for craft household product
design application based upon result through the end of life in the manufacturing
process.
Finally, is manufacturing BP biocomposite as sample product application and
the technique that is applied for manufacturing process capable to help rural small
scale industries in manufacturing craft household product design.
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2.4.1 The Different of Existing Technique Manufacturing Process for Low
Technology for Craft Household Product in Rural Small Scale Industries
This research studied by Hasan, Sahari, & Lucas (2015), is on manufacturing
Sarawak plastic basket and rattan basket that are produced by small scale industries or
rural area industries. Moreover, it is capable of use as the development of light
product application technique and they believe Hot Air blowing technology-
manufacturing process is suitably used to apply for household industries.
Goodner (2015), as researchers in industrial design, they use a waste
component such as Bagasse and Pith (BP) biocomposite as development in the
manufacturing process for craft household product design application. Moreover, their
categories as waste components such as Bagasse and Pith that are disposed of by
hawkers becoming something of value to small scale industries.
Example researcher by M. T. F. Centre (2014) in Kolkata, India, use Leaf Cup
Making Machine as the development pressing in the manufacturing process for low
technology mass manufacturing for disposable plate and cup. In their research, they
use waste dried Banana leaf fibre and Areca Leaf or “Butea Frondoza” leaf as waste
fibre for these manufacturing process.
This low craft technology manufacturing process is the same as cool press
technique that is suitable for use in household product and it uses 3 mm thickness
block and applying trimming and shaping after pressing. In another similar country
such as Bangladesh review by Point (2018), based on their study on waste material
has potential use in gaining the economic impact and they had developed similar
technique use in low technology manufacturing process.
Through these reviews, the material waste such as BP biocomposite from
waste disposal it capable to use in manufacturing utilizing these existing techniques
such as treatment, boiling, baking or curing and Hot Air blowing. Besides, it is able to
use as development technique for HAMP, potential users are rural small scale
industries.
One of example research by Nyawo, Jabulani, & P. B. C. M. (2015), had
promoted Small Medium Micro Enterprise (SME) as small scale sector of craft
production for a local area like in South Africa. They had promoted rural and local
production household products design application such as pottery, plates, doll
weaving, desk coaster, and drinking glass coaster.
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Through their understand the rural sector manufacturing process can be used
as potential to promote tourism and furthermore, the technique used in the rural area
likely are using low technology manufacturing process may help the other local SME
in enhancing their market.
Dissanayake, Perera, & Wanniarachchi (2017), had used as example handloom
technique manufacturing waste craft sheet fabric and lampshade from waste threads to
help small industries in engaging them to promote this technique and technology skills
in the manufacturing process for household product design application.
Another research by Avani (2015), using craft household product design
application like “organic kumkum”, beeswax crayon, silk textiles and non-toxic
watercolour from the waste green component. Additionally, they use extract
technique, water solar heater, and solar dried dyeing for manufacturing technology as
a rural application for their workers.
Some example researchers by Kapur & Mittar (2014); Poon (2017), they have
a study on the revival of Batik that had potential to promote their design for both
domestic and overseas as their target towards of using waste material component by
using natural fibre such as BP fibre. Furthermore, the technique and application use in
the manufacturing process for these handcraft industries is a suitable to use for
household product design application and in extent it potential to develop in the
manufacturing process for especially in mass production.
Through these scholars review, they believe the rural small scale industries
capable to develop their own existing technique as application especially for
household product and they use their manufacturing process as to promote local craft
industries.
The conclusion towards this review, the rural area had use different technique
and technology use from traditional to medium as the application for manufacturing
craft household product design application and is able to improve by developing on an
existing technique. The technology and technique used such as HAMP and Hot Air, it
applicable for manufacturing low technology manufacturing process BP biocomposite
for application based on PVA.
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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
The benefit of development technique by using Hot Air technology reviewed
by Agriculture (2014) use this technology and technique for sterilising glassware to
prevent “bacteria” growth and moreover, in this experiment they had used 180 ᴼ C to
in 2 hours+/- by using Industrial Oven Drying Machine.
Continue review on this Agriculture, (2014), have used as development for
drying in preventing “microorganism” from growing healthy “bacteria” for example
using laminar airflow chamber, incubator machine and autoclave machines as a
decontamination area for this culture. Furthermore, they believe, Industrial Oven
Drying Machine and Ceramic Kiln Chamber can cure BP biocomposite as natural
fibre in manufacturing household product design application.
Before this Chua & Chou (2003), studied on the technology used as small craft
scale industries in developing countries and they had reviewed on natural food dryer
for Soybean, see figure 2.4.2.1. Moreover, in their review on this low-cost technique,
they have recognized three potential tools for curing and drying for the other natural
fibre that is asbestos cement roofing sheet, asbestos rope and mild steel plate as tools
in Slow Design experiment.
Figure 2.4.2.1: Example Air Technology Flow for Natural Food Dryer Kiln Chamber by Patil
and Shukla 1988, (Chua & Chou, 2003)
They believe the development of the manufacturing process such as using
Bagasse and Pith (BP) is capable to cure and dry by using Ceramic Kiln Chamber or
Industrial Oven Drying Machine as the application for household product design
application.
The technique such as drying and curing by Harper (2008) he believes a low-
pressure technique capable use same HAMP towards manufacturing household
product design application. Besides, he had studied the potential of Resin Transfer
Model (RTM) and this researcher had developed technique in the manufacturing
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process for small scale industries into Low Resin Transfer Model (LRTM), using Mild
Steel Plate (MSP) as the platform of his mould, APPENDIX JA p. 240.
These researchers study had agreed by Reddy Nagavally (2016), the
development technique in the manufacturing process such as HAMP from RTM
concept is a suitable low-cost production for craft household product design
application like drink glass coaster, table dish, soft board, pin board, or food bio
absorb cover. However, the hot air technology, it is capable to be used for
manufacturing BP biocomposite and allow it to cure inside of Ceramic Kiln Chamber
or Industrial Oven Dried Machine.
Through these scholars review the benefit in the development of the
manufacturing process such as HAMP is part of an innovative technique for use in
small craft industries especially in a rural area. Moreover, the tools that applicable for
use such as mild steel plate capable to press with Bolt and Nut fastening pressure in
produce BP biocomposite board as craft household product design application using
Ceramic Kiln Chamber and Industrial Oven Drying Machine.
Another researcher believes through development in the manufacturing
process for BP biocomposite board they suggest, “after curing process using a
traditional method such as hot air technology manufacturing process, researcher able
use that board as a medium for design process by cutting and crafting as the potential
of craft household product application”, (Bunnell, 2004).
Bunnell, (2004), also added with the importance on using 3D CAD as tools for
designing product application to help them to communicate with this software and to
get them involved with this development method such as HAMP.
Tann (2015) studied on revival craft technique, like screw printing technique
capable to press for the printmaking manufacturing process and in his study, this
manual technique, are also categorised as low technology development manufacturing
process. The mechanical concept for this manufacturing process depends on fastens,
that presses the print press and through the technique applied. He believes
development in the manufacturing process such as HAMP is capable to print logo or
design on the top of fibre by extruding following mould design.
As the conclusion for this review, the mechanism for producing mould such as
HAMP is based on thickness and the size of the platform that enables Bagasse and
Pith (BP) biocomposite to cure inside 180 ᴼ C in 2 hours +/-. Moreover, based on
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these reviews, by fastening Bolt and Nut is capable to press and safe use for curing in
Ceramic Kiln Chamber and Industrial Oven Dry Machine.
Finally, these researchers also claim these techniques such as hand lay-up
technic and HAMP is a suitable to use for craft household product design application
that is able to give benefit for the small rural sector in enhancing their economy.
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
Reux (2018), have reviewed basic design mould such as Hot Air Moulding
Template (HAMP) tool for manufacturing natural fibre household product application
and this low technology can be optimized through this technical software. One of the
is Autodesk 3Ds Max, Autodesk Inventor, Solid Work, Catia, or Pro Engineer as tools
for the researcher to design HAMP for manufacturing BP biocomposite flat board.
He suggests “a researcher can select from these fives software as tools to
manufacture and design their mould. Furthermore, after designing basic flat mould,
researchers can apply hand lay-up technic on natural biocomposite and add 40 ᴼ C to
270 ᴼ C by blowing it with hot air blower”, (Reux, 2018).
Previously, Mkarand Hastak TaoHoon Hong (2004), they have used low
technology manufacturing process and utilising compression vacuum to compress
natural fibre biocomposite such as BP and in his research. Their claim without high
pressure such as using Bolt and Nut fastening, this technique capable use is for mass
household product design application.
Another research Marshall (2008), and he agree with low technology
manufacturing process capable use as a craft for fabrication in Art & Design, as the
potential of natural fibre such as BP biocomposite for product household design
application.
Strauss, (2013) using 3D CAD application, sees figure 2.4.3.1, it is important
for manufacturer and researcher to explore a potential design that is applicable for this
natural fibre as a prototype. Furthermore, the manufacturer especially for small craft
industries that apply the same technique such as ceramic, and fine art industries using
hand lay-up technic.
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Figure 2.4.3.1: Example 3D View Application in Designing Product Application: a) Stereo
lithograph Parts (STL), b) Editing, c) Line Drawing and c) Material Setup, (Strauss, 2013)
Next, Al Dean, G. Corke & S. Holmes (2016) has reviewed on mould
production as a craft manufacturing process that is porting flat surface need to be clear
from dirt from top and bottom platform surface. Moreover, these researchers
understand each part of the moulding template such as HAMP and are capable to
assemble while in the manufacturing process in BP biocomposite. They suggest the
detail of each part in the usability of mould be defined by technical drawing in 2D
programme such as AutoCAD.
Barati Bahareh & Elvin Karana (2017); Parisi & Stefano (2017), these
researchers have reviewed manufacturing see figure 2.4.3.2 such as lamp shade, bio
absorbs cover, disposable plate, cup, bowl, and coaster as example craft in low
technology manufacturing process such as HAMP. Moreover, they have used this
natural fibre waste such as BP biocomposite by manufacturing basic design flat mould
and the 3D application software their designing this sample as an application for the
product in a rural area small industries.
Figure 2.4.3.2: Example Low Technology Manufacturing Process as Craft Product
Application: from Natural Fibre Biocomposite: a) Flat Heated Coaster, and b) Decoration
Ceramic, (Parisi & Stefano, 2017)
The conclusion, for these reviews by scholars the manufacturing process using
low technology manufacturing processes like HAMP and fastening press, these two
methods are classified as a development manufacturing process.
Beside it is capable for use in mass production for manufacturing BP
biocomposite and, additionally 3D CAD, and technical drawing, is the tool for
manufacturing mould that is applicable to produce simple flat biocomposite board.
With these beliefs, researcher and manufacturer are able to cut the flat board as a
potential use for household design application.
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CHAPTER THREE
METHODOLOGY
3.1 OVERVIEW OF RESEARCH METHODOLOGY
The methodologies are to analyse the method on the bonding of the product.
The task for this experiment, which is through manufacturing of the material for
product development using manufacturing process for BP biocomposite, on another
hand, the research will start by collecting several journals, article, and books,
regarding the project, which is related to process, will be used as reference in the
material lab process.
After the literature review, it will then be submitted into a material process and
conducting several processes, for example, boiling, soaking, drying, blending,
packing, mix, bonding, moulding, and final with a cure. Next, it will go through
material testing after several samples were taken and the tests performed are water
absorption (WA), flexure (FT), and thickness swelling test by collecting data from the
design development. Through this experiment, the outcomes based on a few samples
were obtained as well as the result using lab testing material.
As for the final process by following this method, the researcher needed to
search and cited from previous pattern or journal based previous result through the
test. From the method are product design criteria, which it started with Bagasse and
Pith (BP) biocomposite product design application, product lunch and sell to the
manufacturer. Through this criteria researcher can cite from the previous another
researcher, it can help the designer to start with sketches drawing, technical drawing,
and 3D modelling using such as AutoCAD software.
Finally, after the design process has done the researcher need to end with some
of the example product design application, as the potential for BP composite.
Therefore, the manufacturing processes through this fabrication including General
Assembly (GA) and cutting process for forming a design based on the design sketches
see figure 3.1.1.
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Figure 3.1.1: Research Methodology
3.2 THE PREPARATION MATERIAL PROCESS FOR DRYING
EXPERIMENT
The material preparations for drying BP component from raw sugarcane, have
listed down as a preliminary experiment, which is included with tools and equipment
as the requirement for this preparation as follow the methodology of the process. The
main ingredient in this preparation was BP waste which comes from a collection that
has done disposed by hawker from the night market and the collection by the
researcher.
Some of the tools are used in this preparation such as boiling pot, pales, small
food processor, oven drying machine, and large canvas as to dry the components.
Next, the ingredient from this treatment method in this experiment, the researcher has
used natural class level “Sodium Chloride” (NaCl) and water pipes to treat the
“lignin” in sugarcane properties.
Through this researcher has listed the requirement for this drying process for
both components and thus, this is the first method on the material prepared for these
natural fibres, see table 3.2.1.
Table 3.2.1:
Preparation Material, Tools and Equipment for Drying Waste Sugarcane
Material, Machines and Tools for Drying Bagasse and Pith of “saccharum officinarum”
Materials Units Machines Units
1 unit
Raw Bagasse of “saccharum officinarum” 1.8 kg Small Food Processes Blender
1 unit
(yellow cane) 1.586 kg Oven Dried Machine
Raw Pith of “saccharum 1unit
officinarum”(yellow cane)
1 unit
“Sodium Chloride” (NaCl) Natural Class 20 bags × 350 g Scanning Electron Microscope 1 unit
Level (SEM)
Water Pipe 1000 ml × 5 Chiller
Large Digital Laboratory
Balancing
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Small Digital Laboratory Weight 1 unit
Scale 2 units
Electrical Induction Stove
Small Dry Testing Cup Tools Large Canvases 2’ × 4’ 2 units
1000 ml Regular Plastic Jar Container 12 units Small Digital Laboratory 1 unit
1 unit Balancing
Plastic Basket Strainers Pales 4 units
Mortar and Pestle 2 units Boiling Pots 2 units
Large Plastics Packaging or Large Plastic 1 unit
Boxes 2 units
3.2.1 The Slow Design Experiment Based on Flow Chart Process for Drying
Raw Bagasse and Pith (BP)
In this subtopic, the researcher has drawn a basic flow chart process for the
drying Bagasse and Pith (BP). Therefore the method it is started with the collection of
BP waste, boiling, soaking using NaCl compound, drying, blending, packing final
with BP biocomposite, see figure 3.2.1.1.
Figure 3.2.1.1: Slow Design Experiment based on Flow Chart Process of Drying Bagasse and
Pith (BP) from Sugarcane
3.2.2 The Collection of Raw “saccharum officinarum” (yellow cane)
The original weight of bagasse is slightly different from pith component from
“saccharum officinarum” (yellow cane) taken at night market Bandar Baru Ampang,
Selangor from Malay juice hawker. These fresh BP components weight was measured
using a digital balancing scale placed on top of the flat platform using empty container
and the original weight of BP Biocomposite for bagasse is 1.8 kg and pith 1.586 kg,
respectively. These disposal materials Bagasse and Pith (BP) yellow cane is kept in
Applied Science laboratory see figure 3.2.2.1.
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Figure 3.2.2.1: Fresh Bagasse and Pith (BP) Component from Sugarcane “saccharum
officinarum” are collected from Night Market Bandar Baru Ampang, Selangor
3.2.3 Slow Design Experiment on Conditioning Collection Raw yellow cane
The BP biocomposite was stored in a chiller inside a chiller for three days and
the purpose is to reduce any presence of “fungi” and maintaining the moisture content
(MC) of yellow cane component. Through this experiment, both raw materials are
placed in a separated plastic bag and its place at the same time the temperature for this
experiment is set up between 24 ᴼ C to 20 ᴼC. After the three days, on the next day,
both raw material Bagasse and Pith (BP) raw sugarcane material is carried out from
the chiller.
3.2.4 Slow Design Experiment for Loose “lignin” on yellow cane using Boiling
These experiments were conducted at Applied Science laboratory, UiTM and
the main purpose of this experiment is intended to reduce the loose “lignin” content in
yellow cane and MC percentage. In this Slow Design experiment, the researcher has
used the boiling method and the temperature was set up for 240 ᴼ C using induction
cooking stove in reducing “lignin” that carried inside BP waste yellow cane, see
figure 3.2.4.1.
Figure 3.2.4.1: The Preparation Equipment and Apparatus for Slow Design experiment
through Boiling Method for Fresh BP from Sugarcane: a) Bagasse and b) Pith
The time was set up 8 hours divided by two separated experiment which is 4
hours for Bagasse and another 4 hours for Pith from sugarcane. The preparations in
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this experiment researcher have place bulling pot on the top of induction and fill with
a full raw Bagasse, then inserting a full of a bucket of water pipe. For the next
experiment for Pith, the researcher has done the same previous by setup 240 ᴼ C and
filling up with full of water pipe, takes for 4 hours.
After 2 hours lost, during this experiment, the researcher has filled up again
with a full of a bucket of water for both boiling pots that contain Bagasse and Pith.
This is because, after 2 hours, the boiling water is started to reduced and besides, it
prevented from this bio fibres get burn during the process. Another part is the
induction cook stove it stops automatically after 4 hours and thus, the researcher needs
to setup up again for 240 ᴼ C boil again for 4 hours.
As for the final stage, the researcher has to strain BP waste fibre using a plastic
strainer basket and this is because to remove the water excess after the Slow Design
experiment boiling for both components. Finally, take a weight after the process using
a large digital lab scale and record the weight to get the MC for both components
using a formula to see Moisture Content equation (2).
= − 0 × 100%. (2)
0
3.2.5 Slow Design Experiment for Loose “lignin” on yellow cane using “Sodium
Chloride” (NaCl) Treatment
The researcher has used natural class NaCl in Potential Hydrogen (pH) 7
copolymer using 48% out of 8750 gram (g) or 8.75 kg and only 12 bags out of 25
packets had produced residue inside the tap water. Next, weight percentage used for
each of these bags containing 350 g weight was calculated using the reference
equation (3).
ℎ = ℎ × 100% (3)
ℎ
Then, it was ground using pestle and mortar to reduce its size so that it can
easily dissolve. Next, pour 5000 ml clean tap water inside two empty containers using
1000 ml regular plastic jar container. Then insert every 12 bags ground NaCl into the
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containers that are containing water and put sugarcane Bagasse and Pith bio
components in each container.
Let it set in for 3 days to 4 days +/- for pre-treatment experiment and after the
experiment has done researcher need to strain using large plastic basket strainer to
remove the excess. Finally, weight again using a large digital laboratory scale
balancing to calculate MC, see Moisture Content equation (2), before it dries under
the sun, in large room temperature and Oven Dried Machine.
= − 0 × 100%. (2)
0
3.2.6 Slow Design Experiment using Sun Dried and Interior Air for Dries Wet
Bagasse and Pith (BP) Component from yellow cane
Before it starts, the researcher has to strain the water excess after the Slow
Design experiment for loose “lignin” on yellow cane using “Sodium Chloride”
(NaCl) as a treatment using large plastic basket strainer. Next, place two sets of 8’ ×
4’ large canvas for placing in separated for Bagasse and Pith (BP) wet waste
component directly towards of sun for approximately 8 hours +/-.
The reason why is since the amount of water content is reduced after 3 days+/-
in Slow Design experiment for treatment process for both fibres and researcher still,
need to dry under the sun in 8 hours +/-. Another reason why it is placed in the
exterior environment because it has wind that forces these fibres to dry and not just
heat by the sun.
As for the finale, after 8 hour+/-, the researcher has started to collect these
dries fibres that directly dry under the sun and taking the weight of moisture content
(MC) using the same formula in equation (2). Then the researcher has transferred
these fibres into another place, by using the interior air or in large room temperature.
= − 0 × 100%. (2)
0
The reason why researcher use this interior drying method because these fibres
are still wet and furthermore, the researcher has used separated two large canvases as
to place for these fibres for 3 days before it enters into the Oven Dried Machine.
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3.2.7 Slow Design Experiment using Oven Dried Machine for Wet BP
Component from yellow cane
Before starting Slow Design experiment by using Oven Dried Machine, see
figure 2.3.7.1, the researcher has found that the BP waste from sugarcane that has
done dry using interior air dry and both fibres are still intermediate wet after it left for
three days. To enhance this drying experiment for both fibres Bagasse and Pith (BP),
the researcher has to use Oven Dried Machine to reduce the amount of MC content in
sugarcane (yellow cane).
Figure 3.2.7.1: BP Component Insert into Oven Dried Machine with 100 ᴼ C less than 4
weeks+/-
Through this experiment, the researcher has used a small dry testing cup with
eight sample sets for Pith group and four sets of Bagasse group see figure 3.2.7.2.
Besides, the temperature for this Slow Design experiment by using Oven Dried
Machine it has set up for 100ᴼ C and stays for 30 days that is equal to 4 weeks +/-.
Every three days skipped researcher has recorded all the data weight of Dry
percentage (dry %). However, these fibres have weight using small digital lab lavatory
balancing by using the same formula in Moisture Content equation (2).
Figure 3.2.7.2: Small Sets of Dry Testing Cup for collecting the movement Dry% without
Crush for four samples of Bagasse and eight samples of Pith from “saccharum officinarum”
= − 0 × 100% (2)
0
Another formula that uses in this Slow Design Experiment using Oven Dried
Machine, the researcher has used this Determination Drying percentage equation (1).
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The function of this formula, to determine the total average from the first entering an
end of this drying experiment for both components, or in another term to determine
the total amount of heating percentage reduces towards fibres.
DDR% = dM × 100 (1)
dT
Finale after this experiment has completed for recording all the data dry% for
BP biocomponents and it is ready taking out for the next stage using small motor food
blending process to crush these fibres.
3.2.8 Slow Design Experiment using Blending and Packaging Dried Bagasse
and Pith (BP) Components from “saccharum officinarum” (Yellow Cane)
The blending method through food blending process using to crushing dry
Bagasse and Pith (BP) component has turned both components into biocomposite
particle. The researcher has entered these each dry ingredient about 100 g to 250 g to
blend in separately and this is because the food blending process comes in a small
size.
Next, through this small amount it prevents from this machine broken or stuck
while in the process and furthermore each 10 to 15 minutes, the researcher must note
to press pulse button to rest the machine without overheating the motor.
Then, it has to be packed using plastic bags and stored in the chiller or in room
temperature before it is ready for use. As for the final Slow Design Experiment
through blending, the researcher can use the Scanning Electron Microscope (SEM as
to analyse particle size after the blending process. Besides, the researcher has used
300 Micrometre (µm) to analyse the length of BP biocomposite particle and for the
final, the data length of from both natural biocomposite will be reported through this
experiment.
3.3 THE MATERIAL PREPARATION PROCESS FOR HOT AIR
MOULDING TEMPLATE (HAMP) AND COMPRESSING WIRE
MESH
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The preparation for this Hot Air Moulding template (HAMP), the researcher
has divided three main different domains such as materials, machines and tools use for
designing for this equipment. The main materials used in this experiment such as 8’ ×
4’ (foot) Mild Steel Plate (MSP), bolts, nuts, metal plate, welding rods, grease and
wire mesh.
In machine use, the researcher has the use for cutting, drilling and welding as
the important tools for this process. There are Foot Metal Plate Cutter Machine
(FMPC), Grinder Power Tool Machine (GPTM), Floor Gear Drill Machine (FGDM),
steel chop saw and welding machine with clipper rod. These machines are power up
with electrical power and carefully use when to wear this kind of machine as
following the safety guide use.
Finally, other hand tools also help such as measurement, tightening, and hand
safety, weighing and marking for taking the measurement to see table 3.1.1. As
through end of this Slow Design experiment, a researcher receiving and use HAMP as
equipment for fabrication for BP biocomposite.
Table 3.3.1:
The Material Preparation for HAMP Flattening Wire Mesh
The Preparation for Designing Hot Air Moulding Template (HAMP) and Flattening Wire Mesh
Materials Units Machines Units
8’ × 4’ (foot) Mild Steel Plate (MSP) with 3 1 unit Foot Metal Plate Cutter Machine 1 unit
mm (millimetre) Thickness (FMPC)
Bolts 0.6 cm × 1.5 cm 20 units Grinder Power Tool Machine 1 unit
(GPTM)
Nuts 0.6 cm × 0.9 cm × 20 T 20 units Floor Gear Drill Machine (FGDM) 1 unit
Metal Plate Bars 21’ with 50 mm × 3 mm 1 unit Steel Chop Saw 1 unit
thickness
Rods for Welding 1 bag Welding Machine with Clipper Rod 1 unit
Grease 1 bottle
21’ × 4’ Wire Mesh Size 50 mm × 50 mm 1 large roll
21’ × 4’ Wire Mesh Size 25 mm × 12.7 mm 1 large roll
Tools
Measurement Tape 1 unit Hand Metal Brush 1 unit
White or Black Paint Marker 1 unit Adjustable Spanner 1 unit
Golden Drill Bits 12 mm diameter (Ø) 3 units Eyewear Protector or Spectacle 1 unit
Glove 1 unit Welding eyewear protector 1 unit
Player or Cutter 1 unit Flatten Ballast 1 unit
F- Clamp 4 units Manual Balancing 1 unit
3.3.1 Slow Design Experiment based on Flow Chart Process for Manufacturing
HAMP and Flattening Wire Mesh
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The flow of experiment in Slow Design experiment for manufacturing HAMP,
the researcher has started with the raw material by using MSP as the main component
in forming a mould fabrication for BP biocomposite by through following this flow
chart process sees figure 3.3.1.1 on manufacturing HAMP. The process is started with
the raw material then it follows by the manufacturing that covers measuring, cutting,
drilling, clamping, installing (wire mesh), and assembling as to produce the
components for HAMP.
Figure 3.3.1.1: Slow Design Experiment for Manufacturing for HAMP Mould and
Compressing Wire Mesh
Next, manual hand tools are needed use through designing this HAMP mould
such as using GPTM, cutter or player, clamping using F- clamp for flattening using
ballast and manual balancing. Through these Slow Design experiment, the researcher
has record the data of weight used for this 50 mm × 50 mm and 25 mm × 12.7 mm of
wire mesh. Besides, this wire mesh will be used as the enhancement strength in the
fabrication of BP biocomposite and through the process the BP board will be tested
using American Standard Test Material (ASTM) D 1037.
Additionally, the researcher has used this software such as Eco Material
Advisor (EMa) and Model Checker has potential to analyses on the design of this
mould. The reason for using this software’s is to analysis on “Carbon Dioxide” (CO2)
or carbon footprint and the design of this mould. Through this analysis, the researcher
to decide either need to improve on the form of the design of mould or technique uses
such as using hand lay-up technic.
Finally, as follow through this manufacturing process by following this
procedure Slow Design experiment and the manufacturing mould, it can be used in
fabricating BP biocomposite.
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3.3.2 Slow Design Experiment for Manufacturing Hot Air Moulding Template
(HAMP) Mould
The progression on this Slow Design experiment for manufacturing Hot Air
Moulding template it has to follow the requirement item use and by following the
method process of manufacturing HAMP. The researcher had used a metal plate with
3 mm thickness at UiTM Industrial Design Workshop and these processes are one part
of Life Cycle Assessment (LCA) used as a tool for mass production samples for BP
biocomposite board. These experiments started with metal plate size 4’×8’ (Foot) with
3 mm thickness available at Industrial Design Workshop.
The researcher has taken the measurement and marking each component for
fabricating platform, and bracket using a white marker. These components are applied
using Foot Metal Plate Cutter Machine (FMPC) and drilled using a Floor Gear Drill
Machine (FGDM) that came in separate shapes such as two sets of 30 cm × 30 cm
square platform and eight components of 5 cm × 30 cm × 0.3 cm for brackets design.
Additionally, researcher used Metal Work Drill Bit (MDB) 12 mm+/- in
making a hole for Bolt 3.8cm (L) × 0.6 cm (H) × 0.9 cm (D) × 20 (T) and Nut 0.6 cm
× 1.5 cm installation. Finally, the researcher needs to fasten using accessories by
fastening between left and right brackets for both HAMP mould using an adjustable
spanner. Since HAMP moulding template design is without a frame, thus, it needs
further development.
3.3.3 Slow Design Experiment in Analysing HAMP Mould Design using Eco
Material Advisor (EMa) and Model Checker Software
In this Slow Design experiment for analysing HAMP mould, the researcher
has used Eco Material Advisor (EMa) and Model Checker as software in analysing
form and material of the mould in Life Cycle Assessment (LCA), see figure 3.3.3.1.
First, the researcher started to analyse the form of the mould brought by Inventor 3D
design application and through this analysis, the researcher has assembled it in the
digital screen.
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AB
Figure 3.3.3.1: Analysing Hot Air Moulding template (HAMP): a) Eco Material Advisor User
Interface for Analyse Material and Units Item and b) PTC Model Checker from Pro-Engineer
Software in Analyse the Quality Design Mould Manufacturing Process
However, the analysis is based on the material properties of MSP and the other
components. The component that is including platform, closet, brackets, nut and bolt,
each these components, the researcher has enter based on 3D form drawing and
calculated through this software. The reason, the amount of the material used in this
Slow Design experiment had automatically calculated by this application and through
this analysis, it helps another researcher to let it know the numbers of users in this
design.
Next, after EMa analysis is done, the researcher has used the other software
such as using Model Checker and it is software to help the researcher in identifying
the form of HAMP. Through this analysis, it is helping the researcher to understand
the line section and each cross-section of the design. The 3D drawing in this process is
calculated automatically after it enters into this software and technical 3D are must in
assemble.
As the end of this experiment, researcher will receive results based on this
software and by then the result comes in the draft of the table after it analysed through
this experiment.
3.3.4 Slow Design Experiment for Flattening Wire Mesh as Enhancement for
Fabrication BP Biocomposite
In this fabrication for the wire through the Slow Design experiment for wire
mesh researcher has used two different sizes. The size used is 50 mm × 50 mm and 25
mm × 12.7 mm, these sizes are available at a local hardware shop. The primary of this
fabrication is needed is hand tools as a requirement and by following the method of
flow chart process that had drawn.
The researcher starts with rolling 21’ × 4’ wire mesh on top of the wide area
and then, to maintain it flat, the researcher has pressed it with a foot or place the heavy
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object as to prevent from it rolled back. Secondly, the researcher has cut it using hand
tool player or cutter to cut both wire meshes into 1’ × 1’ or 30 cm × 30 cm and some
of the alternative use researcher have use Grinder Power Tool Machine (GPTM).
After these cutting processes, the next researcher has weight these wire mesh
and record the data weight using manual balancing. Finally, through this fabrication
process of these wire mesh, the researcher will be using it as enhancement strength of
in fabrication of Bagasse and Pith (BP) biocomposite.
3.4 THE MATERIAL PREPARATION PROCESS FOR FABRICATION BP
BIOCOMPOSITE FROM YELLOW CANE
In this experiment, the researcher has prepared a list of the item and
requirement of fabricating BP biocomposite and through this fabrication, the
researcher had separated the materials, machines use and tools as follow this
procedure, see table 3.4.1. The materials including four-litre “Polyvinyl Alcohol”
(PVA), Bagasse and Pith biocomposite, grease, wax paper roll, wire mesh and
disposal roller plastic.
Table 3.4.1:
A Table of Preparation Material for BP Biocomposite Block
The Preparation for Fabricate BP Biocomposite From yellow cane
Materials Units Machines Units
“Polyvinyl Alcohol”(PVA) 4 litre 4 Bottle Ceramic Kiln Chamber 1 unit
“saccharum officinarum” Bagasse 1 large Industrial Oven Dried Machine 1 unit
1 unit
Biocomposite Box 1 unit
“saccharum officinarum” Pith Biocomposite 1 large Circular Saw Machine
1 unit
Box 4 units
1 unit
Grease 1 unit Sander Machine 1 unit
Wax Paper Roll 1 role
Wire Mesh Size 50 mm × 50 mm had cut 30 cm 1 unit
× 30 cm
Wire Mesh Size 25 mm × 12.7 mm 1 unit
had cut 30 cm × 30 cm
Disposal Plastic Sheet Roll 1 role
Tools
Baking Digital Lab Scale Maximum Load 5 kg 1 unit Player or Cutter
Metal Roller Pin 1 unit F- Clamp
Doctor Glove (Alternative) 1 unit Adjustable Spanner
Mixing Bowl 1 unit Small Cup or Small bowl
Next, for this fabrication some of the tools are needed to fabricate BP
biocomposite board such as baking digital lab scale maximum load five kilograms,
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metal roller pin, doctor glove (alternative), mixing bowl, player or cutter, F- clamp,
adjustable spanner, and a small cup or small bowl.
As for the final process of this fabrication, the researcher had cured cutting,
and trimming using these machines such as ceramic kiln chamber, industrial oven
drying machine, circular saw machine, and sander machine. Through this fabrication
and by following this material preparation, the researcher will receive a flat BP
biocomposite board.
3.4.1 Slow Design Experiment Based on Flow Chart Process for Fabricate BP
Biocomposite Board
The flow chart process based on this Slow Design experiment see figure
3.4.1.1, the researcher has used the same raw material after it has ground using a food
blending machine and the researcher has following through this detailing processes.
Figure 3.4.1.1: A Slow Design Experiment based on Flow Chart Process for Fabricate BP
Biocomposite Block
First, these material preparations it starting with dry BP biocomposite, than it
needed to weight such as 30% of “Polyvinyl Alcohol” (PVA), 25% of Bagasse
biocomposite and 25% of pith biocomposite using baking digital lab scale maximum
load 5 kg. Through this weighing, the researcher has used two different equations that
help through this experiment such as PVA percentage use and Cartesian plane as
formulae for mixing these components.
After it is done, the BP dry BP biocomposite is turning into BP dough and
researcher has fabricating using (HAMP) as the tools for fabricating BP biocomposite
board. In these fabricating processes, some of the techniques require using it through
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this manufacturing such as greasing wax papering, layering installing (wire meshes),
cool press and tightening.
Next, after it has done fabricating BP biocomposite block, it needs to cure by
using these two machines Ceramic Kiln Chamber and Industrial Oven Dried machine.
Then the next stage, the researcher needs to use hot air blowing to dry this
biocomposite block to ensure it hardens and has a proper way to hold both natural
fibres.
Finally, after through these processes researcher has received a clean BP
biocomposite block before it ready for testing its material properties using American
Standard Test Material (ASTM) D 1037.
3.4.2 Slow Design Experiment for Mixing Bagasse and Pith (BP) Biocomposite
Dough
The mixing process for fabricating BP biocomposite dough, the researcher had
mixed both fibres using a large of mixing bowl and the main component in these
mixtures was BP biocomposite and PVA. These components researcher have taken
weight using baking digital lab scale maximum load of 5 kg and each of these
components, the researcher has used 25% of BP fibres and 15% of PVA.
The formula to use this experiment for BP biocomposite dough, the researcher
has used these two equations such as Weight PVA Percentage equation (4) and
Cartesian plane equation (10) for mixing BP biocomposite. Through these equations,
it is helping the researcher to calculate the percentage used for these fibres and the
quantity of PVA used.
ℎ = ℎ × 100% (4)
ℎ
2 = (10)
Another 15% of PVA, the researcher has entered 600 g of this solution to
made BP biocomposite dough mixture become lighter and unfortunately, during this
process researcher have added another 25 gram of Bagasse and Pith (BP) dry
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biocomposite. The reason, the BP biocomposite dough is too wet and hard to control it
during this process because the researcher has used a bare hand.
After this mixing process had done, this BP biocomposite dough it has wrap
using disposal plastic sheet roll and researcher properly covered it in preventing
exterior air enter. Through this method, the reason why is preventing from this BP
biocomposite dough absorbing or contact with environment moisture content and store
at room temperature.
Finally, through this experiment researcher will be using this BP biocomposite
dough as to fabricate the BP biocomposite block and including the HAMP as the
mould for this manufacturing process.
3.4.3 Slow Design Experiment for Fabricating Bagasse and Pith (BP)
Biocomposite
Through this Slow Design experiment researcher had used BP biocomposite
dough as to fabricate biocomposite block using HAMP mould and besides another
experiment for curing this biocomposite using two different machines. The curing for
this experiment, the researcher had used Ceramic Kiln Chamber and Industrial Oven
Dried Machine, set up with the same temperature 180ᴼ C with different time use.
The procedure in fabricating BP biocomposite see figure 3.4.3.1, the
researcher has a setup with greasing and wax papering as to prevent for this natural
fibre dough stick on the top of HAMP platform surface.
The preparation for fabricating this BP biocomposite block the right size is 20
cm × 30 cm and this dough is spread at the centre of the HAMP mould. Next, this BP
biocomposite dough researcher has followed the thickness of 3 mm bracket between
left and right as guideline thickness of the BP biocomposite block. After all, the
researcher has used hand layup technic using manual handling hand rolling steel pin
and each of this dough the thickness is 3 mm.
Figure 3.4.3.1: Flattening A BP Biocomposite Dough by using A Roller Pin: a) Flattening BP
Biocomposite Dough and b) Rolling BP Biocomposite Dough
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After it achieves 6 mm thickness, at the second stack of HAMP bracket and
the researcher had installed one layer of wire mesh with two different sizes such as 50
mm × 50 mm cm or 25 mm × 12.7 mm by cutting 30 cm × 30. Then it layers again
with another 6 mm as followed the guideline of brackets. To ensure the wire mesh is
safe without moving, the researcher has pressed with 10 pieces of bolts 0.6 cm × 1.5
cm and nuts of 0.6 cm × 0.9 cm × 20 T.
Then, it needed to tighten for these two components such as bolt and nut using
handling hand adjustable spanner tool, as too tight this component between left and
right of brackets alongside with the closet of this mould. During this tightening
experiment, a cool press also includes trough this fabricates and this is because the
pressured press of the bolts and nuts effect towards of this fabricate. Thus the water
excess from the PVA is removed and because the researcher had place straight object,
enables it to stand about 75 ᴼ.
Thirdly, after the water excess has loosed down, researcher, again open this
HAMP mould by loose these 10 pieces of bolts and nuts between left and right of
brackets using an adjustable spanner. Then, the researcher has to peel this wax paper
both back and front sides of BP biocomposite and press again with these two
tightening components.
Next, the researcher has entered this BP biocomposite into Ceramic Kiln
Chamber and using Industrial Oven Dried to cure this BP biocomposite dough by
turning it into a block. Researcher, have set up for this experiment with different time
with similar temperature 180 ᴼ C and after this curing is done, open this machine door
to let it cool down for 30 minutes before taking out.
Lose these component bolts and nuts from HAMP mould and researcher can
cut the wire mesh excess using the cutter, player or using circular saw machine.
Through this trimming process, the researcher needs to wear a pair of goggle
preventing the spark of wire mesh. Then, the researcher needs to use a hot air gun or
hot air blow, to blow for 30 minutes +/- backside and the front side of this
biocomposite block before it ready for the test.
Finally, after these processes have done and following through this Slow
Design experiment for fabricating BP biocomposite block, the next stage is, the
researcher can ready to test the properties strength of this biocomposite block using
American Standard Test Material (ASTM) D 1037.
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3.5 THE PREPARATION FOR MATERIAL TESTING AND
EVALUATING POTENTIAL DESIGN FOR BP BIOCOMPOSITE
The material preparations in table 3.5.1 for testing Bagasse and Pith (BP)
biocomposite, researcher have cut Samples Block of BP Biocomposite 50 mm × 50
mm × 12 mm (Water Absorption), Samples Block of BP Biocomposite 21.4 cm × 3.5
cm × 1.2 cm (Flexure Test) and Samples Block of BP Biocomposite 50 mm × 50 mm
× 12 mm (Thickness Swelling) by using a circular saw machine.
Table 3.5.1:
A Table of Preparation Testing and Evaluating BP Biocomposite Board
The Preparation for Testing and Evaluating for BP Biocomposite Board
Material Units Machines Units
Samples Block of BP Biocomposite 50 mm × 3 units Instron Machine 1 unit
50 mm × 12 mm (Water Absorption)
Samples Block of BP Biocomposite 21.4 cm × 3 units Circular Saw Machine 1 unit
3.5 cm × 1.2 cm (Flexure Test)
Samples Block of BP Biocomposite 50 mm × 3 units Band Saw Machine 1 unit
50 mm × 12 mm (Thickness Swelling)
Water Tap Sander Machine 1 unit
Small Digital Laboratory 1 unit
Balancing
Software and Soft tools
Autodesk Inventor 1 unit Technical Drawing 1 unit
Sketch Pad 1 unit
Tools
24 cm (L) × 17.9 cm (W) × 5 cm (H) container 1 unit Veneer Clipper 1 unit
Next each of these material tests, researcher have to use Instron machine for
analysing the properties strength of BP biocomposite, water absorption test in 24
hours and taking thickness swelling using veneer clipper following based on ASTM D
1037. Besides, after the researcher has receiving result through these tests, it is
important for the researcher to reviews other previous research papers. Toward this
method, it enables the researcher to search similar result or nearby result as to
determine the potential of the product design application.
Thirdly, after the researcher has determined the potential design using BP
biocomposite and it needed for this biocomposite to design. Some of the soft tools
need to use towards industrial design drawings such as sketching, 3D drawing, and
technical drawing as to the presentation of the form of the product design application.
Next, after these design processes have done, researcher transfer into the BP board
shearing it using a band saw machine and trimming process using sander machine.
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Lastly, after going through these processes, the researcher will receive the
product design application as to claim its potential use as towards of product design
and Hot Air Moulding template (HAMP) as the fabrication tools for this fabrication
for this bio board.
3.5.1 A Slow Design Experiment based on Flow Chart Experiment for BP
Biocomposite Block
This detailing process for Slow Design experiment based on testing BP
biocomposite properties strength it is started with the flexural test (FT), water
absorption test and thickness swelling test. After this testing, the researcher needs to
review on the previous journal based on similar or almost result in these three
experiments whether in the journal, articles or books to search for potential design, as
shown in figure 3.5.1.1.
Figure 3.5.1.1: A Slow Design Experiment based on Flow Chart Process for Experiment BP
Biocomposite
After these reviews have done researcher need to evaluating and
manufacturing the potential design using these tools such as sketching, technical and
3D drawing. Through this flow it is ready for prototyping by using circular saw
machine, sander machine and band saw machine as to form the design for Bagasse
and Pith (BP) biocomposite.
Finally, after through these work progression, the researcher has a simple
prototype design and it is an example of a potential product design application through
this guideline following all these Slow Design experimnt flow chart processes.
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3.5.2 A Slow Design Experiment for Material Testing for BP Biocomposite
Block Properties
The procedure of this Slow Design experiment, the researcher has prepared
three units block of BP biocomposite “saccharum officinarum” 50 mm × 50 mm × 12
mm (water absorption), three units of block of BP biocomposite 21.4 cm × 3.5 cm ×
1.2 cm (flexure test) and three units of block of BP biocomposite 50 mm × 50 mm ×
12 mm (thickness swelling). Moreover, this each of these samples test at the
laboratory using Instron machine (FT) and refill a water tap to record the water
absorption (WA) alongside with thickness swelling (TS) based on ASTM D 1037
guideline.
First, the preparation for the FT test, the researcher has cut this BP
biocomposite 21.4 cm × 3.5 cm × 1.2 cm and the test is set up for 6 mm / 6 minutes.
The 6 mm is represented as the length of the knife and the sample, meanwhile, 6
minutes is the time movement in per second represented, a period of time that must be
fixed to compensate this material until it cracks.
Different from this BP biocomposite 50 mm × 50 mm × 12 mm, the researcher
need to do two tests such as WA and TS. Both of these experiments can be recorded
together and this test researcher had set up for 24 hour that is equal one day. After
these experiments are done, the researcher has use veneer calliper tool to take four
sides of TS result.
Next is, the researcher had also weight this three sample before and after using
this formula Water Absorption equation (11) and through this Slow Design
experiment, the researcher needs to use small digital laboratory balancing as to record
this result. As for the final, the researcher can record the data and made a calculation
by using this equation and for the FT it had automatically calculated by itself by
following this American Standard Test Material (ASTM) D 1037.
(%) = [( 1− )] × 100 (11)
0
3.5.3 The Evaluation of Potential Design based on Previous Reviewers on BP
Biocomposite Product
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The evaluation by reading in previous journals, articles and books, it help
researcher to look on a potential design that is similar or exact as the same result based
in experiment, that done by the researcher. Additionally, the researcher needed to
highlight some of the other potential design that is similar through experimental
results such as WA, TS, and FT.
By cited in the previous search by other researchers, such as the percentage of
WA, the percentage of TS and FT megapascal (MPa), this can conclude the potential
of design as the prototype of the product design application. Half of this process, some
of the tool is important through evaluating as an idea of design using sketching, 3D
modelling, technical drawing and prototyping.
Next, in this design process, the researcher started with sketching the potential
of product design application and it elaborates it using Autodesk Inventor by insert
colour and form as to translate into 3D preview design. Through using these
processes, a researcher can receive technical drawing and 3D view that need to render
using Maxwell Render.
This sketching tool, the researcher will do some experiment by cutting the BP
biocomposite board into 30 cm × 20 cm sizes in shapes of drinking glass coaster that
can be attached together and this prototype of the simple basic design of potential BP
biocomposite utilization using low technology manufacturing process HAMP, as
shown in figure 3.5.3.1.
AB
Figure 3.5.3.1: 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
For other tools involved in this process, the researcher needs to transfer the
sketches into a 3D model by using different software such as Autodesk Inventor, 3D
Max and Maxwell Render for visualization of sample prototype of the manufacturing
process through End of Life (EoF).
The 3Ds Max software is the platform to change the data from Autodesk
Inventor such as Inventor Part (IPT) or Inventor Assembly (IAM) files into 3Ds Max
(3DS file) as the output to be used for Maxwell Studio. Through this software, the
researcher is able to visualise and hence adding a material effect such as colour,
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texture picker in real time daylight based on current location and according to actual
24-hour environmental effect and through.
3.5.4 The Method used in Manufacturing Process for Designing BP
Biocomposite Product Design Application
The preparation on this manufacturing process in designing BP biocomposite,
researchers have cut and trimmed 30 cm × 20 cm × 1.2 cm using this three machine
such as a circular saw machine, band saw machine and Sander Machine. Through this
process, the researcher has cut 130 mm × 130 mm × 12 mm that turned into a square
form and trimming using the sand machine on each edge of this design. The design is
followed by the sketches and based on the technical drawing using Autodesk Inventor.
As for the final process for this manufacturing process, the researcher has done
the experiment, design process and the porotype by using these two locations such as
laboratory and workshop as to manufacturing product design application.
Furthermore, the fabrication technique is applying in these Slow Design experiment,
the researcher has used hand lay-up technic and Hot Air Moulding template (HAMP)
as to fabricate the Bagasse and Pith biocomposite board.
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CHAPTER FOUR
RESULT AND DISCUSSION
4.1 OVERVIEW OF OVERALL OF RESULT AND DISCUSSION
THROUGH SLOW DESIGN EXPERIMENT
In general, this chapter providing an overview of the material manufacturing
process to fabricate BP biocomposite board and the Life Cycle Assessment (LCA) is
part of the manufacturing process. Researchers have designed a framework as a
guideline for product application through mass production and this allow the
manufacturer to be able to follow through the manufacturing process for Bagasse and
Pith (BP) biocomposite.
Another part of this chapter, the discussion on moisture content check on
Bagasse and Pith (BP) will be discussed after it has been tested using the oven dried.
The researcher will detail this result such as determination dry percentage reduction
rate and distribution frequency (Dν) weight gram (w/g). Besides, based on this result
researcher, have to use a Scanning Electron Microscope (SEM) as to analyse the size
particle of these fibres, weight of wire mesh and will be placed through this chapter.
Next, through this conceptual framework, the manufacturer is able to conduct
the collection of raw yellow cane and go through the Slow Design experiment
procedures such as boiling, treatment, air dried, blending, fabricate, moulding, and
curing. The results of this BP biocomposite board manufacturing process will be
discussed for further development as an application in manufacturing craft household
product using hand lay-up technique.
The formula used for this Slow Design experiment in manufacturing BP
biocomposite, the researcher have used this mathematical calculation such as the area
of HAMP mould, the formula percentage of glue used, and Cartesian plane as the
formula for this fabrication. Moreover the temperature use and time as to record all
the result after curing process using Ceramic Kiln Chamber and Industrial Oven Dried
Machine.
Due through this result from this Slow Design experiment, the researcher has
improved the Hot Air Moulding template (HAMP) and the process for fabricates BP
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biocomposite. As for the next stage, the researcher will be discussing with the result of
each test such as flexure test (FT), water absorption test (WA) and thickness swelling
test (TS) for the properties strength of this BP biocomposite board.
For Eco Material Advisor (EMa) and Model Checker as the modus operandi in
analyse the HAMP mould design with including the material used for this
manufacturing process. After this Slow Design experiment is done, the researcher can
start with the design process by using this industrial design tool such as sketching, 3D
drawing, proportion cutting process and preparation of the prototype BP
biocomposite.
Finally, through these Slow Design experiment, the researcher has cited on
previous paper as to declare its potential for this BP biocomposite board. Furthermore,
through this citation, the researcher will be declaring the capability for this product
design application as a household product.
4.2 CONCEPTUAL FRAMEWORK
This conceptual framework is formed based on the LCA framework process.
The conceptual framework shown in figure 4.2.1 had described the full manufacturing
process of BP biocomposite, and through this assessment, it is in consequence with
the Product Development Process (PDP). In this conceptual framework it is cover
with the development of green process such as using HAMP mould, optimization of
the manufacturing process, collected the data experiment as result and including with
prototype of the potential of the product design application.
Figure 4.2.1: The Design Framework for Product Design Application Mass Production using
Low Technology Manufacturing Process
Through this framework, it let the researcher give the result based on the
experiment on each based on the Slow Design experiment. It consists of result for
loose “lignin” on yellow cane using boiling, loose “lignin” on yellow cane using
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“Sodium Chloride” (NaCl), sun-dried and interior air for dries wet Bagasse and Pith
(BP) component and Oven Dried Machine for wet BP component from the yellow
cane.
Secondly, the researcher also has done designing the Hot Air Moulding
Template (HAMP), through this design researcher has received the result on Slow
Design experiment based on using these software Eco Material Advisor (EMa) and
Model Checker. By then, the next step is, the researcher also weight the wire mesh as
the structure of the enhancement strength for BP biocomposite block and use this
component in the fabrication of BP biocomposite.
Next, in the Slow Design experiment for fabrications of BP biocomposite, the
researcher had mixed the entire ingredient and fabricated it with the proper amount
used through the curing process as the result of this experiment. After through this
process, it needs to be tested to receive the result for the material testing and evaluated
the design based on the potential use as product design application.
Finally, as a final result based on this framework in the Slow Design
experiment and it directly Ends of Life (EoF) that lead into the prototype of the BP
biocomposite design application, based on result discussion.
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)
For the first sub-topic of the overview for this Slow Design experiment, the
researcher has started with the boiling water experiment with heated concertation 240ᴼ
C for 8 hours using an induction stove. Moreover, the water used in this experiment,
the researcher had use water tap as the main liquid boiling solution as to loose
“lignin” for both fibres that came from the same green plant, “saccharum
officinarum” (yellow cane).
This experiment has undergone Faculty of Applied Science UiTM Shah Alam,
and as this experiment went through, the researcher succeeds strain this boiling water
tap using a plastic strainer. Next, these both fibres, it has entered with 48% of this
copolymer natural class of 7 pH of NaCl from its original weight and mixed with the
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tap water, as for the final throughout this Slow Design experiment, the researcher
received clean raw BP fibre that has loose “lignin”.
4.3.1 The Result of Slow Design Experiment in Loose “lignin” Content Inside of
Sugarcane by Boiling Treatment
In this Slow Design experiment, researchers have started to boil BP bio
component 240ᴼ C for 4 hour+/- using induction stove as per figure 4.3.1.1. Moreover,
researchers have found that boiling treatment method can cause loss of “lignin”
content from the green plant and it is in accordance to V. K. & S. Sharma (2017) who
stated that natural green bio component such as sugarcane “lignin” can be treated
using this boiling method at high water temperature.
Figure 4.3.1.1: A Boiling Method Applying for Reducing “lignin” Contain in 4 Hour+/- 240
ᴼ C+/- with a Water Pipe
It is also supported by Chou (2015), she has applied more than 100ᴼ C
temperature on loose “lignin” content inside the natural bio component such as
sugarcane and bamboo. Furthermore, researchers have treated this sugarcane for 4
hours+/- with loose “lignin” content inside this green plant and researcher have found
that the water needs to be refilled again after 1 hour+/-.
During this experiment, the researcher has set-up the consistence temperature
of 240 ᴼ C for Bagasse and Pith fresh sugarcane. Furthermore, after 1 hour the water
started to boiled loose “lignin” and Bagasse reaction gave a sweat fragrance or aroma
of sugar that has started to lose. For Pith, the “lignin “made the aroma uneasy odour
because of the interior and exterior of sugarcane skin Pith layer and Bagasse are
mixed together during this boiling process.
Finally, the researcher has done treated these two green waste component and
it needs to strain it by using a plastic strainer to drain the water. Then, for these, both
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components researcher have transferred it to treat with “Sodium Chloride” (NaCl) to
as the next Slow Design experiment.
4.3.2 The Result Discussion on Slow Design Experiment in Loose “lignin”
Content Inside of Sugarcane Pre-treatment Process using “Sodium
Chloride” (NaCl)
In this Slow Design experiment, the researcher had used Weight NaCl
equation (3) to weight “Sodium Chloride” and through this discussion, the researcher
has used 20 bags × 350 g in adding 5 × 1000 ml of regular plastic jar container.
Furthermore, this bio-waste from BP sugarcane each of this container, the researcher
had used the same amount of weight NaCl and let it stayed a room temperature at the
Applied Science laboratory.
ℎ = ℎ × 100% (3)
ℎ
Part of the pre-treatment process, the loose “lignin” content inside sugarcane
was soaked for 3 days+/- and had enabled the chemical compound to react towards
this green plant. Moreover, the researcher had used “Sodium Chloride” (NaCl)
copolymer compound with 48% concentration of Potentia Hydrogen (pH) 7 that
enables “lignin” content inside Bagasse and Pith (BP) component to break.
This is true because NaCl study by Lee (2005), found that this copolymer has
15% strength much better than “Sodium Hypochlorite” (NaClO), and it is supported
by da Silva et al., (2013), that pH 7 concentration enables sugarcane to loose “lignin”
in a natural way because of NaCl properties contained in the “Oxide” (O).
Additionally, after 3 days+/- the colour of the water turned into cloudy as
Bagasse and Pith component had changed into purple colour when the concertation of
NaCl pH 7 reacted towards these green plant. This statement is agreed by Akram
(2017); Rackemann (2014); Warinowski et al., (2016), during this treatment process
“Cell Wall” of sugarcane is exposed that allows NaCl to get oxidized and enables
“lignin” to repel, thus allowing the colour of water surface to change with regards to
this reaction, see figure 4.3.2.1.
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Figure 4.3.2.1: 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
After through this Slow Design experiment, based on the result, the researcher
has started to calculate using this Moisture Content equation (12) and this calculation
is to weight of the wet of Bagasse and Pith sugarcane. By using this formula, the
weight of Bagasse and Pith sugarcane is increasing more than 1000 g +/- and
furthermore researcher, has transferred these two waste green component by dried
under sun-dried.
(%) = [( 1− )] × 100 (12)
0
4.4 OVERVIEW SLOW DESIGN EXPERIMENT OF AVERAGE DRY
PERCENTAGE (DRY %) RESULT FOR BAGASSE USING SUN-
DRIED AND OVEN DRIED MACHINE
During this Slow Design experiment, the researcher has used two different
processes which are using sun-dried and Oven Dried Machine. Through these two
experiments, both wastes from sugarcane BP dried at the same place under the sun for
8 hours. The function of this experiment is to dry the Bagasse and Pith (BP) that have
bailed for over 8 hours and treated NaCl over 3 days +/-.
Thus, the status of these two fibres was actually too wet and the researcher
needed to take another action by using these two methods. Based on using sun-dried
as the experiment for dries this Bagasse and Pith, it gives superior effect towards of
drying this component.
The dry percentage was taken comparing the final day of the 22 days and the
first day readings for BP component that underwent oven-dried machine. The
researcher has produced a four-set of Bagasse dummies and as for Pith, it has eight
sets of dummies and percentages are calculated using the reference equation (12).
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(%) = [( 1− )] × 100 (12)
0
As for the final result of through these two Slow Design experiment, the
researcher has concluded on the result, which is the average of Dry % heated force to
dry on BP “saccharum officinarum” (yellow cane) within 22 days +/- using Oven
Dried Machine.
4.4.1 The Discussion of Slow Design Experiment for Dry Percentage (Dry %)
Result for Raw Bagasse and Pith From Sugarcane using Sun-Dried
The discussion for the Dry% for Bagasse and Pith from yellow cane, the
researcher has done dries these both raw materials after it has treated such using
boiling and treated with 45% of pH value 7 NaCl concentrations. In this Slow Design
experiment, the result, the researcher had placed these raw materials under the sun for
8 hours and the drying process took only for one day. However, some of the raw
material is not dried as promises as it due to the factor of the environment, and this is
because there is certain area overcast.
As it examines for both materials, the researcher had found up raw Bagasse
has a greater wet, which means they're only a few water content is still available. The
cause of this process, during the previous in Slow Design experiment, using NaCl, it
had so very long over than 3 days. Immediately, the Bagasse yellow cane cannot take
very long during that treatment and it is because the more it soaks the greater water
contained absorbs.
Similar from the previous study, Dawson & Boopathy, (2008), claim the
Bagasse cannot soak over than 3 days even a week and to overcome this process it
needs to be squeeze using cheesecloth to force the water excess. Moreover, for the
Pith raw sugarcane are dried much better during this experiment for 8 hours and this
raw material become superior pleasing firm or it became crispy.
As the final of this Slow Design experiment, the researcher has found that
these raw material are still wet, besides it’s transferred this Bagasse and Pith (BP)
material at Oven Dry and the process continues with taking the moisture content using
this Moisture Content, equation (12).
(%) = [( 1− )] × 100 (12)
0
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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
The result for the Bagasse from sugarcane was tested for drying experiment
and had undergone 22 Days+/- oven-dried machine. The temperature used for this
experiment was 100 ᴼ C+/- and the researcher had recorded the amount of W/g of
drying samples.
Next, these Bagasse samples that come from sugarcane are labelled into four
samples such as Bagasse A, Bagasse B, Bagasse C and Bagasse D. These samples
weight and amount of dry percentage (Dry %) value were measured using laboratory
digital balancing scale.
The Dry%, the researcher has labelled “saccharum officinarum” Bagasse
sample A, “saccharum officinarum” Bagasse sample B, “saccharum officinarum”
Bagasse sample C and “saccharum officinarum” Bagasse sample D is as per table
4.4.2.1. Each of this sample has carried out the different value of the weight, on each
of container and the reason why through Slow Design experiment, the researcher had
to determine how much the Dry% heat these fibres.
Table 4.4.2.1:
Sample Weight of Dry% for “saccharum offficinarum” Bagasse A, B, C and D
“saccharum officinarum” Bagasse
Sample Groups of “saccharum “saccharum “saccharum “saccharum
officinarum” officinarum” officinarum” officinarum”
Bagasse
“saccharum Bagasse Sample A Bagasse Sample B Bagasse Sample C Bagasse Sample D
officinarum”
First Day (1st 14.9 g 10. 7 g 13.4 g 39.2 g
Day) 10.4 g 7.6 g 7.9 g 26.9 g
After 22 Days
Total Dry% 43.26 % 40.78% 69.62 % 45.72 %
Heat Force
(Average)
In this Slow Design experiment, all the sample of Bagasse is the same
component that comes from “saccharum officinarum” and through this experiment,
the researcher only determines the amount of heat to decrease wet Bagasse component
the movement Dry% in 22 days +/-.
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The total average Dry% for heating “saccharum officinarum” Bagasse sample
A, B and D, has received 40.78 % to 45.72% as the control variable. However, the
weight for the first day and after 22 days of “saccharum officinarum” Bagasse sample
D is 39.2 g dropped to 26.9 worse than “saccharum officinarum” Bagasse sample A,
B and C.
This is because, the container of “saccharum officinarum” Bagasse sample D
has large space and researcher understood, this container Bagasse sample D also has a
large amount of Bagasse that cover all over the space or too dense.
From the above result, some of the similar study from Naseer Ahmed,
Jagmohan Singh, Harmeet Chauhan & Prerna Gupta Anisa Anjum, 2013), the cause of
this factor, was during this drying experiment in this Slow Design experiment, the size
of the container should be considered. Moreover, they emphasize, a large space
container that contains with a large amount of sample such as Bagasse, the chances for
dries is very poor rather than with a small amount placing with a large of the sample.
However, during this Slow Design experiment for drying “saccharum
officinarum” Bagasse sample D, it received poorly and this is because “saccharum
officinarum” Bagasse sample D is too wet during this experiment. Researcher, also
found that the “saccharum officinarum” Bagasse sample D content of large of water
that capable to squeeze by bare hand.
As for the next discussion is “saccharum officinarum” Bagasse sample A, B
and C, the researcher had understood, that the amount of weight of this sample is too
small and it is also a control variable during this experiment. However, as the result
received, 43.26% to 69.92% is average is the Dry% force heating to dries these
samples and after adequately 22 days +/-, these three samples the control weight is
dropped 10.4 g to 7.6 g from its original weight.
As for the result received, a similar reviewer from A. S. da Silva, Oliveira,
Santos, & Oliveira, (2012), as they had discussed on the weight had taken randomly 5
gram (g) to 7 g. Their claim, if the weight of the sample is too small or as a control
variable, the greater the chances for this raw material such as Bagasse capable to dries
much more constantly.
Final of this Slow Design experiment result by using Oven Dried Machine, the
researcher had found that “saccharum officinarum” Bagasse sample A, B and C is the
control variable. Furthermore, this three sample had received 40.78% to 69.92% is
average is the Dry% force from the Oven Dried Machine, allowed it to dries these
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fibres and due the amount of the weight is dropped 10.4 g to 7.6 g from the first-day
weight took.
The also researcher, claimed this “saccharum officinarum” Bagasse sample A,
B and C is representing all sugarcane Bagasse in the Oven Dried Machine, especially
the heat force Dry% to dries this Bagasse raw material is average of 40.78% to
69.92%.
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
The results for the Pith from yellow cane are based on eight samples treated as
the output from this drying experiment. These samples weights were measured using a
laboratory digital balancing scale and different reading recorded from every eight
samples. These samples were labelled by “saccharum officinarum” Pith sample A, B,
C, D, E, F, G, and “saccharum officinarum” Pith sample H taken from the same
sugarcane source.
Each of this sample have weight by using laboratory digital scale for weighing
randomly “saccharum officinarum” Pith of the eight of samples of Pith such
“saccharum officinarum” Pith sample A is 2.9 g, “saccharum officinarum” Pith
sample B, 7.2 g, “saccharum officinarum” Pith sample C 4.0 g, “saccharum
officinarum” Pith sample D 2.6 g, “saccharum officinarum” Pith sample E 6.5 g.
“saccharum officinarum” Pith sample F 7.2 g, “saccharum officinarum” Pith sample
G is 6.5 g and “saccharum officinarum” Pith sample G is 8.6 g.
These entire of Pith components were dried using Oven Dried Machine under
100ᴼ C and in analysing determine the amount of heat, to decrease wet of Pith
component Dry% in 22 days +/-, see table 4.4.3.1 As shown in below the researcher
have labelled each of the same green plants and this is discussing through on this table
below
Table 4.4.3.1:
Sample Weight of Dry% for “saccharum offficinarum” Pith A to H
“saccharum officinarum” Pith Samples
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Sample Group of Pith “saccharum officinarum” “saccharum officinarum” “saccharum officinarum” “saccharum officinarum” “saccharum officinarum” “saccharum officinarum” “saccharum officinarum”
“saccharum officinarum” Pith Sample B Pith Sample C Pith Sample D Pith Sample E Pith Sample F Pith Sample G Pith Sample H
“saccharum officinarum” Pith
Sample A
First Day 2.9 g 7.2 g 4.0 g 2.6 g 6.5 g 7.2 g 6.5 g 8.6 g
(1st Day)
After 22 Days 2.0 g 6.1 g 3.6 g 1.8 g 5.0 g 4.6 g 5.0 g 6.8 g
Total Dry% 11.5 % 18.03% 11.1% 11.1 % 30% 56.52% 30 % 26.47%
Heat Force
(Average)
Researcher, pick this raw yellow cane dry Pith component and weight as a
control variable for eight samples of Pith “saccharum officinarum” in randomly. Each
of these samples is carried for “saccharum officinarum” Pith sample A is 2.9 g,
“saccharum officinarum” Pith sample B is 7.2 g, “saccharum officinarum” Pith
sample C is 4.0 g, “saccharum officinarum” Pith sample D, “saccharum officinarum”
Pith sample E is 6.5 g, “saccharum officinarum” Pith sample F is 7.2 g, “saccharum
officinarum” Pith sample G is 6.5 g, and “saccharum officinarum” Pith sample H is
8.6 g.
From above, each of these samples comes from the same sugarcane yellow
cane and the weight of these samples, the researcher has recorded it from the first day.
The original dry weight of this Pith component, researcher, have to use Moisture
Content equation (12). Besides, to get the result from this Slow Design experiment,
the researcher had taken the first-day weight and after 22 days +/-.
(%) = [( 1− )] × 100 (12)
0
Through this Slow Design experiment using Oven Dried Machine, based on
the result had given it has different from the beginning taking and after 22 days +/-.
First, for the sample “saccharum officinarum” Pith samples A, C and D it decreases
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from 3.6 g to 1.8 g toward of the heat forcing to dries this sample. Besides, the
average Dry% heating these three samples dropped from 11.5 % to 11.1 % and
through this experiment, as a result, these Pith sample becomes too dried.
Based on the previous study, Bissen, (2009), the heat force in decreasing Pith
Dry% it needs the average of below than 15% from its original and using a constant
temperature, however, if this raw material dropped drastically it becomes very firm.
Next, for “saccharum officinarum” Pith sample B, E, F and G, these samples
have used the same Oven Dried Machine by set up for 100 ᴼ C. Through this four
samples discussion, the raw material Pith also come from the similar plant
“saccharum officinarum”. By then through Slow Design experiment, the researcher
has found, “saccharum officinarum” Pith sample F has the highest Dry rate
percentage (Dry %) by heating this raw material.
Unfortunately, there is a similar result of a total of Dry% from these two
“saccharum officinarum” Pith sample E and G had received 30%. This original
weight for these samples of “saccharum officinarum” Pith sample B, E, F and G, it is
no different from the researcher, initially took a sample of dry weight and up until the
end of the experiment means that after 22 days +/- dried.
But, as the result received from this experiment, 30% to 56.52% from similar
samples “saccharum officinarum” Pith E, F and G the heating force to dry this sample
is average after it takes on every three days by the researcher. Meanwhile, “saccharum
officinarum” Pith sample B, after 22 days +/-, the result of heat force to dry this
sample is 18.03% have slightly decreased 0.15% and comparing from this samples E,
F and G increase 0.49%.
To understand it, this means that samples “saccharum officinarum” Pith E, F
and G the force of heat to dry these samples have a good capability to dry and while
for “saccharum officinarum” Pith sample B, the force of heating this sample by set-up
100 ᴼ C slightly moderately to dried.
For the final, “saccharum officinarum” sample Pith H, researcher took the
same plant of sugarcane yellow cane, and it has slightly different from the other
samples “saccharum officinarum” Pith A to “saccharum officinarum” sample G. This
sample, researcher has taken 8.6 g and after 22 days +/-, this sample has dropped 6.8
gram. The force to heating this sample is 26.47% and rather than “saccharum
officinarum” Pith sample B is 18.03%.
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The weight of “saccharum officinarum” Pith sample B, the researcher had
taken 7.2 g, as the end of 22 days +/- it decreases to 6.1 gram (g) and through this
discussion; the researcher has found that the first day of these two samples has a
significant difference in initial weight. The initial weight for “saccharum officinarum”
Pith sample B is 7.2 g and “saccharum officinarum” Pith sample H is 8.6 g.
As after 22 days +/- these samples of “saccharum officinarum” Pith sample B
and “saccharum officinarum” Pith sample H, the total of heat force to dry this Pith
sample is moderate increase 0.45%. This mean, these samples are slightly slow to dry
rather than similar plant “saccharum officinarum” Pith sample A, C, and D, easier to
dries because the Pith skin layer is thin, even it can be crushed by barehanded.
Next, for “saccharum officinarum” Pith samples E, F and G the drying result
has good effects in rather than “saccharum officinarum” Pith sample B and H.
Besides, these samples the Dry% heat force only 18.03% to 26.47% to dries these
components. This is because, the two samples E and G from these three samples have
the same amount of initial weight and the “saccharum officinarum” Pith samples F
has 56.52% better heat Dry% force to dry towards this component, using Oven Dried
Machine.
Finally, as the conclusion of these discussions on this Slow Design
experiment, all the samples come from the same plant which is (yellow cane)
“saccharum officinarum” and in addition, the amount of weight toward of this Slow
Design experiment, the researcher took by randomly.
Towards on this experiment, the researcher also claimed that the Dry% heat
force average for samples “saccharum officinarum” Pith samples A, C, D, E, F and G
is representing all sugarcane Dry% Pith in the Oven Dried heating force is average of
11.5 % to 56.52%.
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
The overview for this Slow Design experiment is discussing on the detailing of
Dry percentage (Dry %) movement, for these two raw fibres to dry in every 3 days
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from the 22 days +/- to one-month using oven drying machine. The researcher also
haven done collected all the data dry decreasing Moisture Content (MC) movement on
every 3 days and recorded using a bar chart.
In this section, the researcher is discussing on four samples of Bagasse and
eight samples of MC% loss within 22 days +/-. This entire sample it came with a
similar green plant of sugarcane “saccharum officinarum” (yellow cane) and this
Slow Design experiment, is dries using Oven Dried Machine available at UiTM Shah
Alam.
The determination of reduction rate is to analyse the trending of dry percentage
for BP component within 22 days+/- and the percentage is calculated using reference
Determination Drying percentage, equation (1). Through this end of the discussion,
the result is based on the average movement of MC loss every 3 days for Bagasse and
Pith (BP) raw component dried.
DDR% = dM × 100 (1)
dT
4.5.1 The Result Determination Dry Percentage Reduction Rate (DDR %) for
Bagasse Component from Yellow Cane
For Determination of Dry Reduction Percentage Rate, for Bagasse component
from yellow cane, four samples were produced using the same oven drying machine
and these four samples were dried for 528 hours that is equal to 22 days+/-.
These four samples were labelled as “saccharum officinarum” sample Bagasse
A, “saccharum officinarum” Bagasse sample B, “saccharum officinarum” sample
Bagasse C and “saccharum officinarum” sample Bagasse D. All these samples come
from the same plant, which is yellow cane Bagasse and these samples stay at Oven
Dried Machine for 22 days +/-, in figure 4.5.1.1.
Figure 4.5.1.1: Determination Dry Reduction Percentage Rate (DDR %) for “saccharum
officinarum” samples Bagasse A, B, C, and D
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To take the average result for this raw material, the researcher had taken the
weight each of these samples using laboratory digital balancing scale. Using this
equation (1), it helps to determine the average Dry% loss for these four samples of
Bagasse and as a data record, the researcher has concluded that are discussing in this
study based on the bar chart.
DDR% = dM × 100 (1)
dT
Based on these four samples result, the control variable is “saccharum
officinarum” sample Bagasse A, “saccharum officinarum” sample Bagasse B and
“saccharum officinarum” sample Bagasse C. While the highest Determination Dry
percentage (DDR %) rate is “saccharum officinarum” sample Bagasse D and through
this Slow Design experiment.
The result based on the graph for saccharum officinarum” sample Bagasse A,
“saccharum officinarum” sample Bagasse B and “saccharum officinarum” sample
Bagasse C the average of DDR % was 10.43% to 7.68%. Rather than, “saccharum
officinarum” sample Bagasse D, after the dying experiment done in 22 days+/- and
the result, based on the graph overall average DDR% loss was 28.93%.
The discussion based on the result saccharum officinarum” sample Bagasse A,
B and C, in a good condition without any burn or damage after it dries in 22 days +/-.
Additionally, Same as the previous study, Anwar, (2010) cited to Anwar, (2005)
through on drying this Bagasse component “saccharum officinarum”, they had
received below than 20% from an original weight of DDR % loss and besides, they
have dries this Bagasse for over than 10 hours using Oven Dried Machine.
Next, the result saccharum officinarum” sample Bagasse D, the highest
amount DDR% which it received 28.93% and this are because the Bagasse is too wet,
even it can be squeeze that containing water. Through this result based on this
discussion from previous study Abdalla, Hassan, & Mansour, (2018) these group
research had cited Mwakali et al., (2006) and through experiment result that they
received 50% DDR%, unfortunately still wet condition.
The reason of this result saccharum officinarum” sample Bagasse D is wet
according to Jackson A Mwakali et al., (2006), air heated more than 100 ᴼ C to force
this wet raw material to dry. Finally, as the discussion through this Slow Design
experiment in analysing the average DDR % for Bagasse from “saccharum
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officinarum” sample A, B and C is the control variable which is received less than
20% in 22 days +/-.
4.5.2 The Result Determination Dry Percentage Reduction Rate (DDR %) for
Pith Component from Yellow Cane
Determination Dry Percentage Reduction Rate (DDR %) for samples has
labelled “saccharum officinarum” Pith sample A, B, C, D, E, F, G to H of Pith, all of
these samples come from the same plant of yellow cane and these samples, has dried
using Oven Dried Machine. With the same temperature set 100ᴼ C in 22 days+/- or
around 528 hours and these samples, only focusing on Pith of sugarcane, which is the
skin of sugarcane to determining the DDR % for this raw material, as shown in figure
4.5.2.1.
Figure 4.5.2.1: Determination Dry Reduction Percentage Rate (DDR %) for “saccharum
officinarum” sample Pith A, B, C, D, E, F, G and H
The average of DDR % of samples “saccharum officinarum” Pith A,
“saccharum officinarum” Pith C and “saccharum officinarum” Pith D, based on
these three samples, it dries very drastically between to other five of Pith’s from the
similar plant “saccharum officinarum” that come from the same green plant. The
range of this sample dropped very dry and capable to break, due to the properties are
too firm even can be crushed by bare hand. Moreover, these three samples have an
average dry loss from the first day until the last of 22 days these dropped to 2.08 %,
3.04 % and 3.93 %.
From above the result received, based on this discussion on J. Seena, M. Jacob,
(2006) research, after these fibres were washed away with water, soaked and dries for
a long period of time, the strength of this fibre strand chain properties also capable
loose down and dries too long make it easy to break firmly or even crashed with
blade.
Next for the “saccharum officinarum” Pith E, “saccharum officinarum” Pith
F and “saccharum officinarum” Pith G, these three samples is classified as an
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intermediate dry class after its dries for 22 days. As the researcher, analysis these three
results based on the graph as the data collected, found that DDR % was controlled and
from the previous sample saccharum officinarum” Pith A, “saccharum officinarum”
Pith C and “saccharum officinarum” Pith D is too dry.
The reason for these three similar samples from Pith’s fibre of (yellow cane),
that had labelled “saccharum officinarum” Pith E received 6.60%, Pith F is 6.40 %
and G is 6.43 %. However, the initial weight of these fibres was controlled from
previous three samples such as “saccharum officinarum” Pith F is 7.2 g, “saccharum
officinarum” Pith E and saccharum officinarum” Pith G is 6.5 g and. In significantly,
the range these three samples the average total dry loss for 22 days was only 19.32 %.
Sivara, (2016), at this point of Pith DDR % were controlled a variable dry
cause, he understands that the Pith fibre was categorized as semi-moist that need to
add numbers of day to ensure it stops at a certain range of the target dries.
Furthermore, he suggested to dries more super effective using Fourier Transform
Infrared Spectroscopy (FTIR) in analysing the properties of these fibres.
For samples “saccharum officinarum” Pith B and “saccharum officinarum”
Pith H, the total of DDR % after it dries in 22 days found it is higher than the others
Pith samples such as “saccharum officinarum” Pith A, C, D, E, F and G. Moreover
the total of as it done calculated it has received 7.36% and 8.37 % for these two
samples and however the original weight was taken, the researcher found about 1.61 g
weight successful lost for these fibres dry.
As for the conclusion for these DDR % based on this search only sample
“saccharum officinarum” Pith A, C, D, E, F and G is categorized as successful, and
the reason is for the sample “saccharum officinarum” Pith E, F and G even is semi-
moist, however it still can force dries, next for the similar sample “saccharum
officinarum” Pith A, C and D were too dries rather than sample Pith B and sample
Pith H because the properties of these two fibres is still wet after 22 days dry using
oven dried.
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)
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The distribution frequencies (Dν) are to analyse the average of weight gram
(W/g) dried for Pith sample and Bagasse dummies via yellow cane using the oven-
dried machine. By using these methods the accuracy of total average W/g of BP
component became accurate using the total target of dry percentage.
This is in parallel with what has been claimed by Mechlouch, Mahdhaoui,
Elfalleh, & Mahjoubi (2014); Satchell & Turner (2010), whom had used these Dν to
analyse the total average Weight Gram (Wg) of green sample, and the total dry
percentage using dummies for Bagasse and Pith from yellow cane. Due to using Dν as
to calculate frequency, to analyse the movement of every three days for Bagasse and
Pith of yellow cane to dry inside Oven Dried Machine, besides after every three day,
the researcher is able to take W/g.
The Bagasse has four come from the same green plant as it labelled by
“saccharum officinarum” Bagasse A, “saccharum officinarum” Bagasse B,
“saccharum officinarum” Bagasse C, and “saccharum officinarum” Bagasse D. In
addition, another eight samples of Pith from the same green plant, the researcher have
labelled “saccharum officinarum” Pith A, “saccharum officinarum” Pith B,
“saccharum officinarum” Pith C, D, E, F, G and H.
As the end of this the entire of these samples, the researcher has calculated
using the Dν as frequency every 3 days of movement moisture (MC) weight loss and
the final for this calculated found that the entire of final MC for Bagasse was achieve
7.04 % and Pith was 6.5 %. Through this calculated it all the entire of four samples of
Bagasse and eight samples of pith, it is represented the entire of these samples that are
dried in the Oven Dried Machine are a success.
4.6.1 Overall Distribution Frequencies (Dν) Movement of Bagasse “saccharum
officinarum” Dried Every 3 days
On this table as shown in table 4.6.1.1, the researcher has done taking every
three days of dry Bagasse from the same green plant “saccharum officinarum” and
moreover, the weight loss, the researcher has labelled by W/g 0 to Wg/ 4. Each of this
sample the researcher pick randomly as initial starting W/g0 and after three days, the
researcher comes to the lab by taking the weight after.
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Table 4.6.1.1:
A Table Distribution Frequencies (Dν) of Bagasse “saccharum officinarum”
Overall distribution frequencies (Dν) Movement of Bagasse Every 3 days
All Sugarcane (yellow cane) Bagasse W/g 0 W/g 1 W/g 2 W/g 3 W/g 4
“saccharum officinarum”
“saccharum officinarum” Bagasse Sample A 14.9 g 10.4 g 10.4 g 9.1 g 10.3 g
“saccharum officinarum” Bagasse Sample B 10.7 g 7.6 g 7.6 g 7.1 g 7.6 g
“saccharum officinarum” Bagasse Sample C 13.4 g 9.3 g 9.1 g 7.9 g 9.2 g
“saccharum officinarum” Bagasse Sample D 39.2 g 29.6 g 29.3 g 26.9 g 27.8 g
Total Overall Distribution Frequencies (Dν) Bagasse Through Oven Dried
39.2 g 1 10.3 g – 10.7 g 4 • Total Overall Sample Tests =
26.9 g – 29.6 g 4 9.1 g – 9.3 g
13.4 g – 14.9 g 2 7.1 g – 7.9 g 4 4 Similar sample of Bagasse
5 “saccharum officinarum”
• Mode = 5 The Lowest Wet
% Lost out of 20 Trials
• Final Target Overall MC%
for “saccharum
officinarum” Bagasse =
7.04%
First, “saccharum officinarum” Bagasse sample A, have done recorded and
found that the range W/g dropped from 14.9 g to 9.1 g, however W/g 1, W/g 2 and
W/g 4 as it calculated it drops only 1 g only due to this, based on the above researcher
will further discussion in this subtopic chapter.
As the first day it Wg/ 0 taken, the original weight was 14.9 g, but unfortunate,
after three days from similar samples of bagasse W/g 1 and W/g 2 have decreased
similarity to 10.4 g. Furthermore, another three days lost, this sample dropped once
again at W/g 3 is 9.1 g and unfortunately this “saccharum officinarum” Bagasse
sample A after adds another three days it increases again at W/g 4 are 10.3 g.
This is because; the researcher found that W/g 4 it does not move at certain
period to force it dries even after its add another three days to complete in 22 days,
however, it does not budge and through this, understand by the researcher, it is
because it has achieved the capability for this “saccharum officinarum” Bagasse
Sample A too dry. It is true that the average of every three days toward this sample is
controlled weighing at range W/g 1, W/g 3, and W/g 4 from the original.
Next for the “saccharum officinarum” Bagasse sample B, as taken by
randomly, the researcher has started with 10.7 g and after every three days after its
records it was controlled dry weight at W/g 1 to W/g 4. Throughout this discussion,
these samples W/g 1, W/g 2, W/g 3, and W/g 4, after weighing it decreased from its
original weight. Moreover, the, as it recorded based on this sample result the
movement after every three days, W/g 1, W/g 2 and W/g 4 are stayed in maintaining
7.6 g from the original weight 10.7 g.
121
“Saccharum officinarum” Bagasse sample C, it has almost the same as
“saccharum officinarum” Bagasse sample A weight is taken only the different it is
added 1.5 g and however, W/g 1, W/g 2 and W/g 4, these resulted is controlling every
three days. The range of these three days was dropped from the original weight 13.9 g
and after 6 days past it dropped again from 9.3 g to 9. 1. After adding another three
days in force by dropping from 9.1 g to 7.9 g and it increased again after three days to
9.1 g.
Previous study Abdalla et al., (2018), the properties of this Bagasse from
sugarcane yellow cane increase due to its properties contain the available of 50% of
moisture content after it forces by the oven heat and moreover, another reasoned this
property bio-absorbed towards environmental air, so this physical characteristic of
sugarcane properties cannot be changed.
As the final dry result for “saccharum officinarum” Bagasse sample D, the
researcher has taken same as the other sample i.e. randomly and as it recorded, the
researcher had taken 39.2 g as the starting the original weight for this sample. As it is
gone to every three days W/g 1, W/g 2 and W/g 3 dropped 29.6 g to 26.9 g. However,
it increases back 27.8 g, thus as it mentions from this researcher found that the
properties of this fibres have superior absorb toward air moisture.
As for all for these “saccharum officinarum” Bagasse sample A, B, C and D,
these samples were totally dry on every three days after the researcher recorded and
moreover after it calculated by using distribution frequency (Dν). The mode was 5 as
represent 7.1 g – 7.9 g the most dry after it went 20 trials and the conclusion is, after it
can dry by using Oven Dried Machine the highest mode as it represented all the entire
of Bagasse in the oven are totally dry as the final target moisture content (MC%) is
7.04 %.
4.6.2 Overall Distribution Frequencies (Dν) Movement of Pith “saccharum
officinarum” Dried Every 3 days
As shown in table 4.6.2.1, is similar sample green plant from “Saccharum
officinarum” Pith, the researcher had labelled “Saccharum officinarum” Pith sample
A, “Saccharum officinarum” Pith sample B, “Saccharum officinarum” Pith sample
C, D, E, F, G and H. This entire sample is the same plant from “Saccharum
officinarum” (yellow cane) and the researcher had taken these fibres by randomly
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“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),
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