THE UTILIZATION OF DRIED CORN(Zea Mays) STALK AS AN

ECO-FRIENDLY ALTERNATIVE TO CARDBOARD PRODUCTION

A Science Investigatory Project

Presented to

South Philippine Adventist College

Academy Department

By:

FRANCINE GWEN S. GABUTERO

SAMUEL FLORO L. PAMBALAN

BERN ALISTAIR D. MORADOS

KURSTEIN KISH M. MERCADO

SOFIA ISABELA ACABA

X – Venus
- Background of the study

These days the influx in demand for products sold via online methods are ever increasing,

requiring more use of cardboard boxes. The cardboard industry faces environmental challenges

due to the reliance on conventional pulp sources. Deforestation, energy-intensive processes, and

environmental impact pose concerns. While cardboard is recyclable, improper disposal can lead

to landfill issues. In landfills, cardboard waste can generate methane gas, a potent greenhouse

gas that contributes to climate change. Corn residue, comprising stalks, leaves, and cobs left after

corn harvest, is a readily available and usually neglected agricultural byproduct, remains

underutilized. Burning the corn residue is a normal practice in people but burning corn residue

releases particulate matter and other pollutants into the air, contributing to air pollution. This can

have negative effects on respiratory health and overall air quality in the surrounding area.

Investigating its suitability as a pulp for cardboard production presents an opportunity to address

environmental issues and promote sustainable practices within the packaging industry.

In this study we primarily aim to utilize the dried corn stalk as a main ingredient as it

contains cellulose, hemicellulose, and lignin which are needed for cardboard production and the

corn stalk has the strongest fibers in a corn plant which is essential for the strength of the

cardboard. Abundant and renewable, corn residue offers an opportunity to shift towards more

sustainable economy practices. Its unique fiber composition makes it an intriguing candidate for

cardboard material. One of the goals of this research is to support the development of more

responsible and resource-efficient practices within the packaging industry. This study aims to

give value to corn residue as an environmentally friendly, sustainable, and cost-efficient

alternative material in production of cardboard instead of being neglected or improperly

disposed. This study also aims to provide insight to other future researches to collect information

or to improve the study or as well as industrialize the process.

- Research Questions

1. How can you say that corn stalk cardboard is eco-friendly and what are its effects in the environment
compared to traditional cardboard?

2. How good of an alternative is corn stalk cardboard compared to traditional cardboard? What are its
differences in terms of tensile strength, thermal insulating abilities, etc.

- Methodology

1. Materials and Equipment

a. Dried corn stalks(3kg.)
b. Water(15 liters)
c. (50g.) Cornstarch as binder
d. Blender or grinder
e. Large container or vat
f. 50mm. by 50mm. wooden frame and screen or mesh for forming sheets
g. Large sheets of cloth
h. Press or rolling equipment

2. Research Method

We will test the durability, tensile strength, and other principle of the corn stalk cardboard compared to
conventional cardboard. We can achieve results in the form of stretching, tearing, and clumping the
cardboard. For its environmental effects we will examine the corn stalk cardboard’s composition and
determine whether these components can have harmful effectsl to the environment. We will also test its
economic impact and value to the production of cardboard, as well as test for if it is practical in our
generation or present time.
3. Procedures
- We first harvest dried corn residue after a corn harvest or it can also be dried in the sun if it is still
green, after this we remove the leaves as we primarily want the stalk for its stronger fibers, the removed
leaves can be a great feed for livestock.

- We then add 3kg. of the corn stalks to a vat and submerge it in water and let soak for 1 hour to soften it
for the pulping process.

- After done soaking slowly blend or grind and break down all the stalks and turn it into a fibrous pulp.
After, we then add the pulp into a large vat with 15 liters of water and add 50g. of cornstarch as a binder.

- For the straining tool, make two 50mm. by 50mm. frames using wood and staple a 50mm. by 50mm.
mesh on one frame, the other frame will only be held on top of the mesh when straining the pulp.

- After pulping we can form the paper sheets, using a straining tool, use the tool to scoop up some pulp
and letting the water seep through leaving behind the fibers, repeat a couple of times until the desired
thickness is achieved.

- After straining we then transfer the sheets of fiber onto a sheet of cloth and adding a cloth on top for the
next sheet of fiber, repeat until desired amount is achieved. After, use a press tool on the stack to squeeze
out all the excess water and let dry in the sun until completely dry.

- After drying, carefully peel the now sheets of paper from the cloth and collect them and prepare them
for the making of cardboard.

- For the cardboard making process there are three layers, we first layer a sheet down, after, we take
another sheet and fold it to make a zigzag pattern and glue it onto the first sheet with a zigzag pattern
fold, this layer gives extra support and improves the overall strength of the cardboard, lastly we glue on
another flat sheet of paper on top of the second layer, thus creating a cardboard.