Author(s)
P.A. Mbah
- ISSN (P): 3139-8464
- Manuscript ID: 140955
- Volume: 2
- Issue: 8
- Pages: 247–269
Subject Area: Engineering
Abstract
The pressing environmental challenges posed by conventional petroleum-derived plastics have accelerated the exploration of sustainable alternatives, particularly biocomposites derived from agricultural waste. This investigation focuses on the development and performance optimization of a rigid biocomposite material composed of polypropylene (PP) reinforced with palm kernel shell powder (PKSP) a readily available lignocellulosic byproduct of the palm oil industry. The target application is rigid food service and packaging products such as plates, trays, cups, containers, and lids. PKSP underwent comprehensive characterization prior to composite fabrication with maleic anhydride-grafted polypropylene (MAPP) enhanced PP. Composite specimens measuring 15 mm × 15 mm × 100 mm were produced through melt mixing followed by compression molding, with PKSP concentrations ranging from 5 wt% to 25 wt% across three particle size fractions: 75 µm, 250 µm, and 500 µm. Tensile properties, specifically strength and modulus, were rigorously assessed using an electronic Universal Testing Machine (UTM-YYL016) in accordance with ASTM protocols. Monte Carlo optimization algorithms, executed through custom Python programming, were subsequently applied to identify the optimal particle size and loading combinations that maximize mechanical performance. The analysis yielded three distinct optimized formulations: (75 µm, 25 wt%) offering the most favorable strength-stiffness balance at 166.77 MPa·GPa; (75 µm, 5 wt%) exhibiting peak tensile strength of 35.60 MPa; and (500 µm, 25 wt%) demonstrating maximum tensile stiffness of 5.64 GPa. Experimental outcomes reveal that PKSP incorporation markedly improves composite stiffness, accompanied by a modest, acceptable decline in tensile strength a characteristic behavior in particulate-filled systems. These findings substantiate PKSP as an economically viable, environmentally sustainable reinforcing agent for polypropylene, thereby confirming its practical applicability in rigid food packaging. This work contributes meaningfully to agricultural residue valorization, fosters circular economic models, and promotes the advancement of eco-friendly polymeric materials for packaging applications.