Compression Molding of Phenolic Resin and Corn-based DDGS Blends

With the rapid growth in the ethanol fuel industry in recent years, considerable research is being devoted to optimizing the use of processing coproducts, such as distillers dried grains with solubles (DDGS), in livestock diets. Because these residues contain high fiber levels, they may be amendable to incorporation into bio-based composites. Thus, the goal of this study was to demonstrate the viability of using corn-based DDGS as a biofiller with phenolic resin, in order to produce a novel biomaterial. DDGS was blended with phenolic resin at 0, 10, 25, 50, 75, and 90%, by weight, and then compression molded at 51 MPa (3.7 tons/in2) and 174 °C (345°F). Molded specimens were then tested for tensile strength. Tensile yield strengths ranged from 32 MPa (4,700 psi) to 7.6 MPa (1,100 psi), while the engineering strain ranged from 0.6% to 1.25%. Results indicate that DDGS concentrations between 25% and 50% retained sufficient mechanical strength and thus represent reasonable inclusion values. Additionally, data were similar to those from other studies that have investigated biofillers. Follow-up studies should quantify the effects of altering molding parameters, including molding pressure, temperature, and time, as well as pretreatment of the DDGS. Additionally, strength of the DDGS composites should be optimized through the use of coupling agents or other additives.