Production of Packaging Materials by Recycling of Corn and Common Reed Fibers with the Addition of Wollastonite: Structural and Mechanical Properties

Yerlan Doszhanov, Adilkhan Orazbayev, Murat R. Zhumabayev, Saule Kaldybayeva, Aigerim Kerimkulova, Aliya Alimbetova, Nariman Pravin, Arman Zhumazhanov, Aitugan Sabitov, Ospan Doszhanov

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Dauren Baiseitov

Recycling, 2026

Full text Open access: Gold Metadata (CSL-JSON)
DOI 10.3390/recycling11060096
Data confidence 85 high
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Abstract

This study explores the possibility of making cardboard and molded egg carton packaging from corn residues and common reed as alternatives to wood-based pulp. Six formulations were made: corn husks (CHs), corn leaves (CLs), corn leaves (35%) plus corn husks (30%) and a corn blend (15%) of wollastonite (CaSiO3) (CH + CL + W), a corn blend (CH + CL: husks 60%, leaves 40%), mixed corn waste (MCW) and shredded common reed (SR). Optical microscopy was used to evaluate the fiber morphology, including the calculation of the flexibility coefficient, the cell wall rigidity and the Runkel ratio, for raw materials and fiber after alkaline hydrolysis and casting of egg cartons in silicone molds. The grammage, burst strength and index, folding endurance, thickness and moisture content were measured in the cardboard samples, while warping, compressive deformation, moisture and ink absorption were measured in the egg cartons. The flexibility coefficient of the common reed fibers (64.5%) was better than that of the corn fibers (23.6%), and so was the Runkel ratio (0.86 vs. 1.2). In the case of cardboard formulations, the maximum burst strength (462.4 kPa) and the maximum burst index (3.0 kPa·g/m2) values were obtained with the MCW formulation, and the highest folding endurance (42 and 38 double folds) was obtained with the CH and SR formulations, respectively. The addition of wollastonite improved folding endurance to 28 double folds and reduced moisture content to 4.1%, whereas the moisture content was reduced but burst strength decreased to 250.5 kPa. Egg cartons made from corn were found to satisfy all the requirements tested for good packaging, while the reed-based cartons were found to have inadequate ink absorbency time (20 min), making them less printable. Overall, mixed corn residues seem to be the most promising raw materials for sustainable packaging, and wollastonite can be used to adjust the flexibility–strength balance.