Eco-design and Life Cycle Assessment of Japanese Tableware from Palm-Melamine Bio-composites

Palm waste upcycling has become a national policy due to the increase of palm oil plantations for alternative energy production. Because of the large waste volumes of 5.4 million tons per year, this study explores the potential use of palm wastes for innovative materials and eco-products as well as their commercial applications. The concept of eco-design was applied at the very beginning of designing phase by considering the use of waste as raw materials. Currently, there is no alternative application of palm wastes beyond being incinerated for heat or being turned into particleboards. The potential impacts from transport were minimized in the production of tableware by sourcing palm wastes from local palm mills at the nearest location. Processing procedure of fiber preparation included sundrying and grinding the palm fiber, followed by steam explosion (pressure at 18 bars, temperature at 200 °C, for 5 min). After that, the treated fibers were ground to the smallest size (lesser than 0.1 mm) to be mixed homogeneously with melamine compound. The ratio of palm fiber compound varied from 10, 20, and 30 % by weight. The goal of the new compound aims at maximum fiber content that complies with eco- or bio-based environmental product declaration. There are two sets of design: origami (inspired by a Japanese paper folding) and organic (inspired by mushroom forms). The new palm-melamine bio-composites were tested for their qualities in accordance with the required industrial standards: TISI 1245. Using palm fiber of 10 % of the total weight gave the best quality results, while the higher fiber content failed for water absorption as well as acid resistance tests. To facilitate the commercial application, the optimal production conditions at the lab scale were adjusted for actual industrial processes of a local melamine manufacture. Life cycle assessment (LCA) was performed to ensure that the use of palm-melamine bio-composite had the potential reduction on all impact categories. Prototypes were made and carbon footprinting was performed to support the environmental product declaration in terms of kgCO₂e per piece. Through the integration of eco-design and LCA, the tableware from palm-melamine bio-composites has been developed and supported with environmental footprint information, so that customers can better engage in environmental practices.