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Replacement of Polyethylene (LDPE) and Wax Coating in Paper Cup by Alternative Coatings

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Replacement of Polyethylene (LDPE) and Wax Coating in Paper Cup by Alternative Coatings International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 1 January 2017 Replacement of Polyethylene (LDPE) and Wax Coating in Paper Cup by Alternative Coatings Dr. M. K. Marichelvam M.E., Ph.D1* M.Nagamathan2 1ASSISTANT PROFESSOR 2 RESEARCH SCHOLAR DEPARTMENT OF MECHANICAL ENGINEERING DEPARTMENT OF MECHANICAL ENGINEERING MEPCO SCHLENK ENGINEERING COLLEGE MEPCO SCHLENK ENGINEERING COLLEGE SIVAKASI SIVAKASI ABSTRACT The disposable cup which is made out of paper and often lined with plastic or wax to prevent leaking and soaking of liquid from the cup. Drinking in the LDPE paper cup causes some of the health effects and also the environmental effects. The health wise effects are due to the high temperature of the hot beverages at 93 o C which is poured inside the cup which leads to the changes in film property from hard glossy material to soft rubbery material. The environmental effects are due to the burning of these used paper cups which contains LDPE film leads to the formation of toxic gases and high amount of carbon dioxide evolved which causes severe health problems. To find out these severities various tests are taken and calculated the effects by the analysis. In this work, the replacement of LDPE film in the paper cup is done by applying some of the natural gum products from the seeds of plant. Here the guar gum is selected among the various gum products based on certain criterion. The coating compositions are chosen by getting guidance from the guar gum manufacturing industries and also on the basis of trial and error method. After this the guar gum is prepared according to the composition and tests the various parameters like water absorption capacity and thermal resistance of the coating. For all the compositions made the results showed that the guar gum coating is not fit for the paper cup which is need to become a leak proof coating for the drinking beverage. KEYWORDS: Plastic, Wax, LDPE film, Guar seed, Guar gum, Hot beverages 1. INTRODUCTION A paper cup is the disposable cup which is made out of paper and often lined with plastic or wax to prevent leaking and soaking of liquid from the cup. The base paper for paper cups are called cupboard and are made of special multi-ply paper machines and have a barrier coating for waterproofing. In the earlier stage, paper cups for hot drinks were glued together and made waterproof by dropping a small amount of clay in the bottom of the cup, and then spinning at high speed so that clay would travel up the walls of the cup, making the paper water resistant. However, this resulted in drinks smelling and tasting of cardboard. Cups for cold drinks could not be treated in the same way, as condensation forms on the outside, then soaks into the board, making the cup unstable. To remedy this, cup manufacturers developed the technique of spraying both the inside and outside of the cup with wax. Clay and wax coated cups disappeared with the invention of polyethylene (PE) coated cups; this process covers the surface of the board with a very thin layer of PE, waterproofing the board and welding the seams together. Most paper cups are designed for a single use and then disposal. Very little recycled paper is used to make paper cups because of contamination concerns and regulations. Since most paper cups are coated with plastic (polyethylene), then both composting and recycling of paper cups is uncommon because of the difficulty in separating the polyethylene in the recycling process 2. PROBLEM IDENTIFICATION The following are the various problems which is due to the use of polyethylene coated paper cups, The LDPE film of density 0.910–0.940 g/cm3, withstand a temperature range of 80 °C continuously and 85°C for a short time. But the maximum temperature of serving hot drinks is about 85°C and 93°C. 19 Dr. M. K. Marichelvam , M. Nagamathan International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 1 January 2017 Paper wastes are comes under the regular waste which is burnt or put in landfills. Due to the presence of plastic film, it will take more years to degrade. While burning these paper cups, dioxins are produced. It is a highly toxic pollutant, which causes cancer. 3. METHODOLOGY Review the literatures related to the paper cup. Based on the literatures, the problems are identified. Then the paper cup is initially tested with Differential scanning calorimetry to find the exact melting point of the LDPE film which is composting with the paper board. It is compared with the actual temperature of the hot drinks which being served. Then the substitute for the PE film will be developed by using guar gum and applied over the paper board and test the various parameters various parameters like Thermal resistance and Surface water absorption capacity. Then using the starch from various food products like Rice, potato, beans, and corn, a starch based coating is produced to apply on the paper board. The developed coatings are then fed under test to measure the various parameters like Thermal resistance test and Surface water absorption capacity. Finally the coating which is offering high resistance to withstand at elevated temperature and loss water absorption capacity is chosen as the best one. 4. RESULTS AND DISCUSSIONS THERMO GRAVIMETRIC ANALYSIS: From the results obtained from TGA, the mass loss for the LDPE granules is found out at various temperature ranges, which is from the room temperature to the coffee brewing temperature (93o C) and is presented in table. Percentage of weight loss SAMPLE TEMPERATURE (o C) WEIGHT OF THE SAMPLE % 31.09 99.78049 40 99.70539 60 99.56097 80 99.46855 93.01 99.5552 Calculation: (Weight Loss) • Sample Weight = 3.728 mg • Initial weight % = 99.780 • Weight at 93.01 o C = 99.555 • % difference in weight = 0.225% • Weight loss at 93 o C = (3.728/99.780) X 0.225 = 0.0084mg TGA Analysis: • LDPE chemical formula = –(CH2-CH2)n– • Monomer = CH2=CH2 20 Dr. M. K. Marichelvam , M. Nagamathan International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 1 January 2017 (CH2)2 FOOD GRADE LDPE Granule TGA Graph • Atomic weight for C = 12.011 • Atomic weight for H = 1.007 • Total weight of (CH2)2 = 2 (12.011 + 2(1.007)) = 28.05 # 1 Test: (CH) Total weight of CH = 12.011 + 1.007 = 13.018 % of CH in (CH2)2 = (weight of CH/ Total weight of (CH2)2) X 100 = (13.018 / 28.05) X 100 = 46.40 % (Not Matched) # 2 Test: (C) Total weight of C = 1.007 % of CH in (CH2)2 = (weight of C/ Total weight of (CH2)2) X 100 = (1.007/ 28.05) X 100) = 3.59% (Not Matched) 21 Dr. M. K. Marichelvam , M. Nagamathan International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 1 January 2017 # 3 Test: (H) Total weight of H = 12.011 % of H in (CH2)2 = (weight of H/ Total weight of (CH2)2) X 100 = (12.011/ 28.05) X 100) = 42.82% (Not Matched) RESULT: The calculated % for CH, H, C are not matched with the % difference in weight (0.225%). So finally it is concluded that % difference in weight is due to the adsorbed water (Moisture) over the subjected LDPE granule material in the TGA device pan. The LDPE granule material is safe at 93 o C which is highest temperature in a coffee maker machine. PREPARING AND APPLYING THE COATING: COATING 1: The coating composition is based on the UNICARE PHARMACY COMPANY, CHENNAI. APPARATUS REQUIRED: Magnetic stirrer with heater Weighing machine Beaker Dryer COATING COMPOSITION: Coating composition (By weight ratio) 1:4 Mesh size = 100 mesh Paper board = 200 GSM • 4 gram of water • 1 gram of guar powder • Heating and stirring at 80 o C for 1hr RESULT: At the mid time of the process, it forms lumps and residues in the mixture that create the stirring action to fail. COATING 2: The coating composition is based on the UNICARE PHARMACY COMPANY, CHENNAI. APPARATUS REQUIRED: Magnetic stirrer with heater Weighing machine Beaker Dryer COATING COMPOSITION: Coating Composition (By weight Ratio) 1:4 Mesh Size = 200 mesh Paper board = 200 GSM 1 gram of guar powder 4 gram of water 22 Dr. M. K. Marichelvam , M. Nagamathan International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 1 January 2017 Heating and stirring at 80 o C for 1hr RESULT: Lumps formation is in fewer amounts compared to 1st coating, but the stirring action is completely blocked after drying the coating, it came out from the applied board. So this coating composition is failed. Here after the mesh size of 100 is rejected due the residue formation COATING 3: This coating composition is based on trial and error method due to the lump formation in the coating 1 and 2. Here the volume of water is correctly find out to suit with spraying method, that means there is no lumps in the mixture that allows it to spray through the nozzle. And also small amount of glycerin is added to the mixture. The glycerin has the plasticizer property. The purpose of adding glycerin is to make the mixture yield like a plastic. The amount of glycerin is find out by adding it from 1 gram and tested in between the process of mixing by the rough paper board, whether the required amount is reached or not.
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