Rebirth

keywords: Sustainability, Agricultural Waste, Bio-material, Material Design, Packaging.

Materials: Rice Straw, Sugarcane, Jute.

Design category: Material Design, Design Research, Strategy, Product Design.

Time: May, 2019.

Overview:

Rebirth is a bio-material designed for sustainability, made from agricultural waste, sugarcane, and rice straw in particular. The straw would otherwise be burned in large rural bonfires, decreasing air quality, contaminating groundwater tables and reducing soil fertility.

Rebirth uses this straw as a natural resource to design bio-degradable, locally sourced material manufactured in the form of sheets. Thinner sheets exhibit cardboard-like properties, whereas thicker sheets can be equivalent to MDF and wood. It can be mold-pressed, laser-cut, and dyed. The project has explored applications, street food packaging, plant pots, and surface material based on equipment that would be readily available in rural China.

*Rebirth - Processed with carpentry machines*

*Rebirth - Proportion tests with adhesive*

Project background

China is the largest grain producer in the world. It produces over 700 million tonnes of straw waste in a single harvest season. The straw waste is mostly used as fertilizer which isn't ideal as it can encourage crop pest infestation. It can also increase GHG emissions in the form of methane by 22-210% due to straw stimulation. Restriction standards being raised in rural areas have had a punitive impact on the local economy. There is a crucial need for agricultural waste to be repurposed as only 3% is used as a raw material (see figure 1 below).

Project goal

Rebirth was developed to contribute towards a circular bio-economy and offer an economical and environmental solution. Rebirth would allow for 20% of the waste to be reutilized as a resource. The straw would otherwise be burned in large rural bonfires, decreasing air quality, contaminating groundwater tables, and reducing soil fertility. The straw waste can be utilized in situ. It would also allow for removal from the field within a short window between harvesting and planting a subsequent crop. It can be manufactured in the form of sheets in micro-factories in rural areas.

This figure illustrate the use of straw. Around 20% of straw is kept in remain each year. Most of the waste is still using as fertilizer and fodder.

The disposal of the materials of Rebirth. And their geographical distribution within China.

Although, Chinese government sets limits for farmers to deal with the waste, straw disposal remains the huge issue for farmers.

The production of the material.

The key takeaways from the proof of context stage are (Test One):

1. Moisture content is high and the material needs at least 3 weeks to dry (Result of Test One, please see following images)

2. Natural adhesives identified: agar, pine resin, dextrin

3. Small fibers respond better than larger fibers

4. Straws used: rice, wheat, sugarcane

Test two & three:

1. Natural adhesives identified: Rice Glue, Casein, Paper Clay

2. The material can be made into flat sheets easily, but not in irregular shapes

3. The use of heat-pressing helps to speedup drying process and solved the problem of materials from getting moldy. Material status turns out to be stable

4. However, material can be over-heated and cracked easily because of the humidity and steam during the heating process

(the order of the following galleries are, paper clay, casein and rice glue & Test Three - rice glue further developments)

Final test (to be continued):

Rebirth is designed to be manufactured in the form of sheets in micro-factories in rural areas. I have also created variations in the recipe so that it can be produced at home in the form of plates for farmers with smaller landholdings. Factory visiting contributes to Rebirth according to find out an appropriate technique based on the scale of the factories.

Properties of the material:

1. It is lightweight

2. Releases significantly fewer fumes, when subjected to heat, driven processes like laser cutting

3. Decomposes without leaving any contaminants

4. You can use a high temperature (150C) to remould the material

5. Can be stained or dyed

6. Absorbs oils and reverts to the original state when it dries

7. Flexibility reduces for thicker sheets. Restrictions noted for 2mm and higher

4. Recyclable

Further description:

Rebirth can be made into sheet material in different thickness, and some irregular shapes (more tests need to be done). Thinner sheets exhibit cardboard-like properties, whereas thicker sheets can be equivalent to MDF and wood. It can be mould-pressed, laser-cut, and dyed.

The recipe can also be replicated at home with some guidance, using metal sheets in a heat-press technique. Hence it can be mass-produced in cooperatives or cottage industries. It decomposes without leaving any contaminants, and you can also use a high temperature to remould the material.

The project has explored applications based on equipment that would be readily available in rural China. As pointed out by Shandong Provence Circular Economy Association, utilizing those wastes or byproduct as resources is a sustainable solution to problems.

The needs and challenges of farmers are not well considered when developing the funding structure for such a scheme. Environmentally friendly alternatives produced from straw waste depends on an extensive support for straw collection, transportation, storage, and utilization at a regional or provincial level, which is mostly non-existent. The development of infrastructure requires large investment and expertise. There is a high risk of being found guilty but open-field burning remains an inexpensive and readily available option for farmers. They would rather be fined or detained as they can not afford to miss the plantation or other options.

Stakeholders & Benefits:

The image above shows how Rebirth can work not only as a product. It offers an opportunity to build up the connections between farmer, companies, factories and users.

How it works (2 ways):

1. The grain grows in the fields

2. Harvest

3. Collect and deliver to manufactures

4. Process the raw material and make the product.

5. Product is being made.

6. Product is used and discarded

7 -1. Compost

8 -1. Recycle again

9. Collect and deliver to the manufactures & remake to new products

7 -2. Littering

8 -2. Trash disposal - burning or being buried.