Development of Molded Fibers-Based Packaging from Sugarcane Bagasse for Sustainable Alternatives to Single-Use Plastics

Abstract

Molded fiber-based packaging has recently surged in popularity as a replacement for single-use plastics (SUPs). However, key challenges include the lack of low-cost, high-yield sustainable fibers that provide adequate strength and moldability while reducing drying energy consumption, which is essential for widespread adoption. Therefore, this study explores high-yield, sustainable fiber development for molded packaging applications through carbonate and bicarbonate pulping, as well as oxygen delignification. Furthermore, it examines mild refining and cationic starch treatments to balance strength and drainage properties during the molding process. Results show that carbonate and bicarbonate pulping of sugarcane bagasse achieved yields of approximately 72%, while oxygen delignification reduced yield by 2% but improves mechanical performance by 25%. Mild refining decreased dryness by 10%, whereas adding 1% cationic starch enhanced dryness by 9% and increased mechanical strength by up to 60%. These alternative fibers from sugarcane bagasse present a viable solution for replacing SUP packaging, helping to mitigate pollution and reduce waste accumulation.