CHAPTER I

INTRODUCTION

A. Background of Study

In order to successfully form plastic masses, the use of additives and

processing aids have always been a must. Binders have been called the most

important processing additive of the Ceramic Sintering Process (also firing) and

along with other additives (Cerchio, 2006). The role of the binder includes

aggregation and holding the different whiteware components during the firing

process to acquire clean and uniform heating while providing exceptional green

strength to the sintered parts.

Ceramic Binders are quite expensive and the utilization of Ceramic

binders from local and cheaper materials is also quite a necessity considering the

low economic status of different countries especially, Philippines. Carboxymethyl

Cellulose (a kind of binder) costs $2000-$3000/metric ton (Market Price, Hefei

Changming Co., Ltd. 2011) and are even imported from outside the country thus,

the price increases and is multiplied when it reaches the local market. The

Researchers of the study plan to use the Jackfruit peeling as the raw material of

the target alternative binder. Almost all the parts of the Jackfruit tree including its

fruit secretes latex when injured which is a good factor when it comes to binding.

The Jackfruit peeling itself also contains cellulose which is the chief component

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of plants’ cell walls. Cellulose products such as the Carboxymethyl Cellulose are

used as binder.

The study will evaluate the effectiveness of Jackfruit peeling as the raw

material for an alternative binder. Furthermore, the study will determine the

plasticity, liquid and plastic limit of the standard whiteware mass that will be used

for the plastic mass formulation.

B. Statement of the problem

The study will evaluate the feasibility of the Jackfruit peeling as an

effective raw material in the formulation of alternative ceramic binder to standard

whiteware plastic mass.

Sub-problems

1) What are the characteristics of the new plastic masses using water as

ceramic binder and the characteristics of the new plastic masses using

jackfruit pulp as ceramic binder in terms of their:

a. shrinkage

b. modulus of rupture

c. loss on ignition

2

2) Is there a significant difference between the plastic masses using water and

jackfruit pulp as binder?

C. Hypotheses

a. There is no significant difference between the new plastic masses using

water and jackfruit pulp as binder.

b. The alternative binder utilized from Jackfruit peeling is not an effective

raw material of the said formulation.

c. The plastic mass formed with the use of the alternative binder utilized

from Jackfruit peelings is not comparable to plastic masses formed with

use of artificial binders.

D. Objectives of the study

The study aims:

1. To determine the effectiveness of the Jackfruit Peeling as raw material to

alternative binder.

2. To determine the shrinkage of the new plastic masses formed with binder

utilized from Jackfruit peeling.

3. To determine the modulus of rupture of the new plastic masses formed

with binder utilized from Jackfruit peeling.

4. To determine the loss on ignition of the new plastic masses formed with

binder utilized from Jackfruit peeling.

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E. Significance of the study

Considering the low economic status of many countries especially

Philippines, the need of producing alternative products in place of commercial

products have been the main pursuit of many researchers nowadays. The

importance of ceramic binders, as a part of a growing industrial country became

more apparent because of the growing needs of ceramic engineering that requires

ceramic binders, and the goal of the researchers in this study to produce a better

alternative material using the Jackfruit peeling as the raw material came in as one

of the good solutions on contributing in the economic growth of the country.

Since we import binders from outside the country, having an alternative and

cheaper binder is major step in our economy.

Besides the future contribution of this study to our economy, this study

also aims to lessen the waste level production in our society. Successfully coming

up of a way of utilizing waste products such as usually disposed jackfruit peeling

into useful products like alternative binders is also a major step in solving one of

the major problems of the country – too much waste disposal.

Since Jackfruit peeling is one of the fruit which is abundant in our country,

using it as a raw material to alternative binders is one way of promoting our own

products. This study will open many opportunities especially in the field of

ceramic engineering in our country and give way to the production of binders in

our country.

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The ceramic engineers in our country will no longer need to import

ceramic binders which will decrease the production price of plastic masses and

thus also decreases the price of plastic masses (porcelains, plastic wares and the

like) in the local market.

The success of this study will also give way to the exportation of binders

outside the country which will improve the net profit of the businessmen in the

country thus also improving the salaries of both employees and employers of

businesses in the field of ceramics thus again, will contribute to the economy our

country.

F. Scope and Limitation

This study will utilize the Jackfruit peeling as the raw material to the

alternative binder; it will be mixed with water to form an alternative binder. The

study will also focus on the determination of shrinkage, modulus of rupture and

loss on ignition of the new plastic masses using water and jackfruit pulp as

ceramic binder.

G. Definition of Terms

Jackfruit

a species of tree in the Artocarpus genus of the mulberry family

(Moraceae). Jackfruit peeling is used in our study as the source of

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cellulose and latex that will be the main materials needed in producing

binders.

Cellulose

a complex carbohydrate, or polysaccharide, consisting of 3,000 or more

glucose units. The basic structural component of plant

cell walls, cellulose comprises about 33 percent of allvegetable matter (90

percent of cotton and 50 percent of wood are cellulose) and is the most

abundant of all naturally occurring organic compounds. In ceramic

engineering, cellulose products such as Carboxymethyl Cellulose are used

as binders. Besides its latex content, jackfruits also contain cellulose.

Binder

is a ceramic ingredient which binds or holds the ceramic particles such as

clay particles and powder particles. It also gives dry and wet strength to the

body of ceramic particles. It will be the goal of the study to produce an

effective alternative binder using the jackfruit peeling as a raw material.

Ceramics

a term applied to all useful or ornamental clay objects that are baked. It

includes both pottery and porcelain. Any clay object fashioned from earth

and hardened by baking, either in the or by firing is considered pottery.

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This study encompasses the formation of ceramics since it includes firing

process.

Shrinkage

is the rate at which the body shrinks during drying and firing. This

characteristic is interrelated and affected by the clay body formulation and

by the firing time and temperature. This study will use the determined

shrinkage of the new plastic masses using jackfruit peeling and water as

binders to evaluate the effectiveness of jackfruit peeling as raw material to

alternative binders.

Modulus of Rupture

is the ultimate strength determined in a flexure or torsion test. In a flexure

test, modulus of rupture in bending is the maximum fiber stress at failure.

This study will use the determined modulus of rupture of the new plastic

masses using jackfruit peeling and water as binders to evaluate the

effectiveness of jackfruit peeling as raw material to alternative binders.

Loss on Ignition

is a test used in inorganic analytical chemistry, particularly in the analysis

of minerals. It is designed to measure the amount of moisture or impurities

lost when the sample is ignited under the conditions specified in the

individual monograph. . This study will use the determined loss on

ignition of the new plastic masses using jackfruit peeling and water as

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binders to evaluate the effectiveness of jackfruit peeling as raw material to

alternative binders.

Standard Whiteware Plastic Mass

a pre-mixed clay made of 25% ball clay, white clay, feldspar and quartz

(Valencia L.T., 2006). Standard Whiteware Plastic Mass will be formed in

the study using jackfruit peeling as its binder. Its Plasticity, Plastic Limit

and Liquid Limit will be determined and will be used as reference in

evaluating the feasibility of jackfruit peeling as binder to Standard

Whiteware Plastic Mass.

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CHAPTER II

REVIEW OF RELATED LITERATURE AND RELATED STUDIES

The jackfruit (Artocarpus heterophyllus or A. heterophylla) is a species

of tree in the Artocarpus genus of the mulberry family (Moraceae). It is native to

parts of Southern and Southeast Asia. It is the national fruit of Bangladesh,

(locally called Kathal). The jackfruit tree is believed to be indigenous to the

southwestern rain forests of India. It is widely cultivated in the tropical regions of

Indian subcontinent, Vietnam, Thailand, Malaysia, Indonesia. Jackfruit is also

found in East Africa e.g. in Uganda and Mauritius, as well as

throughout Brazil and Caribbean nations like Jamaica. It is well suited to

tropical lowlands, and its fruit is the largest tree-born fruit, reaching 80 pounds

(36 kg) in weight and up to 36 inches (90 cm) long and 20 inches (50 cm) in

diameter. The jackfruit tree casts a very dense shade. Heavy side branching

usually begins near the ground.

Outside of its countries of origin, fresh jackfruit can be found at Asian

food markets, especially in the Philippines. It is also extensively cultivated in the

Brazilian coastal region, where it is sold in local markets. It is available canned in

sugar syrup, or frozen. Dried jackfruit chips are produced by various

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manufacturers. In northern Australia, particularly in Darwin, Australia, jackfruit

can be found at outdoor produce markets during the dry season. Outside of

countries where it is grown, jackfruit can be obtained year-round either canned or

dried. It has a ripening season in Asia of late spring to late summer.

All parts of the tree exude sticky white latex when injured. The latex

contains resins that may have use in varnishes. The latex also has bacteriolytic

value comparable to that of papaya latex. Additionally, the sticky latex is used for

trapping birds (birdlime) and for insect traps. The heated latex can be used as glue

for mending chinaware (a kind of whiteware known for its high strength and

impact resistance and also for low water absorption – all deriving from the high

glass content) and pottery and as caulking for boats and buckets. (Elevitch &

Manner, 2006)

Whiteware is any of a board class of ceramic products that are white to

off-white in appearance and frequently contain significant vitreous or glassy

component. Whitewares are often referred to as triaxial bodies, owing to the three

mineral types – clay, silica/flint and feldspar – consistently found in their makeup.

Clay is the plastic component, giving shape abilities to the unfired product and

also serving as a glass former during firing. Flint is the common name used in the

industry for all forms of silica serves as a filler, lending strength to the shaped

body before and during firing. Feldspar serves as a fluxing agent, lowering the

melting temperatures of the mixture. These raw materials are mixed with ceramic

binders to hold them together and keep them intact during processing and firing.

This is necessary until the whiteware processing is complete.

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A ceramic binder is a processing additive. In ceramic processing, binders

are the polymer molecules and coagulate colloidal particles that are adsorbed and

bridges between ceramic particles to provide inter particle binding action.

An adsorbed binder may improve the wetting of the particle. A binder

usually increases the apparent viscocity of the processing. The settling of particles

in suspension may be reduced on adding binders. The flow properties of slurry

can be controlled but binder type and concentration. The most important function

of the binder is to improve the as-formed strength of the product for handling

before firing. (Huang 2006)

Table 1 Type of Binders

Colloidal Particle Type

Organic Inorganic

Microcrystalline Cellulose Kaolin, Ball Clay

Molecular Type

Organic Examples Inorganic Examples

Polysaccharides Refined Starch Soluble Silicates Sodium Silicate

Polymerized Alcohol Polyvinyl Alcohol Organic Silicates Ethyl Silicate

Polymerized Butyral Polyvinyl Butyral Soluble Phosphates Alkali Phosphate

Acrylic Resins Polymethyl

Methacrylate

Soluble Aluminates Sodium Aluminate

Glycols Polyethylene Glycol

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Adding ceramic binder during processing and firing is also necessary to

improve the shrinkage of the material.

Shrinkage is the rate at which the body shrinks during drying and firing.

(Zamek 2003)

Drying shrinkage refers to reduction in dimension of new concrete,

dimensional lumber, cement plaster, plywood, asphalt paving and other materials

which have dried or experienced significant reduction in moisture content. (Geary

2011)

Firing Shrinkage on the other hand refers to the reduction in dimension

during firing.

Modulus of Rupture is the measure of the force necessary to break a

given substance across, as a beam, expressed by eighteen times the load which is

required to break a bar of one inch square, supported flatwise at two points one

foot apart, and loaded in the middle between the points of support. (Rankine

2011)

The feasibility of certain binders can also be tested using the Loss on Ig-

nition (LOI) test as it was used in a previous study titled “The Feasibility of

Marang Peeling as Binder to the Standard Whiteware Plastic Masses” by David

Dwight Alip. (Alip 2007)

Loss on Ignition test is designed to measure the amount of moisture or

impurities lost when the sample is ignited under certain conditions. (Zaidan 2011)

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Another related study was conducted to determine the plasticity, liquid

limit, and the plastic limit of the plastic masses using water and marang pulp as

binder. It was titled “Evaluation of the Marang Peeling as Binder to the Standard

Whiteware Plastic Masses”, and it used marang pulp (considering its latex

content) as the main raw material of the binder used to form standard whiteware

plastic masses instead of commercial/expensive materials. A comparison was

made between marang pulp and water as binder to standard whiteware plastic

masses. Based on the results of the study, the researcher concluded that there was

no significant difference between the plastic limits of the plastic masses with

respect to the plastic masses (new and aged) and the type of binder being used.

The plasticity of the plastic masses also has no significant difference with respect

to the plastic masses being used. However, the type of binder used has a highly

significant effect in the plasticity of the plastic masses. Regarding the liquid limit,

results of the study have shown significant difference between the liquid limits

using different binders. (Cabili, 2007)

(To find another alternative binder that can be used as a binder to standard

whiteware plastic masses, the researchers of the present study will use Jackfruit

Peeling instead of Marang Pulp as binder to standard whiteware plastic masses.)

Another study titled “Leatherette from Jackfruit Peelings” was conducted

with the purpose of making leatherette utilizing only ripe jackfruit peelings and

gelatin. The leatherette produced showed characteristics similar to that of genuine

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leather. The said study also sought to determine the effects of the relative

amounts of gelatin to jackfruit peelings on the effectiveness of the leatherette. The

leatherette made was subjected to different tests namely, tests for pliability,

porosity, quality and force applied. Based on the results obtained from the study,

it was concluded that the more gelatin added, the stronger the leatherette. Usage

of binders other than gelatin was also recommended. It was also recommended

that the latex present in the jackfruit can be utilized as a binder. (Padate, 2001)

(The information gathered regarding the effectiveness of Jackfruit Peeling

as the raw material of leatherette on the said paper will be used as a reference by

the researchers of the present study.)

The related literature and the related studies gathered supports the idea of

jackfruit peeling as an effective binder to standard whiteware plastic masses since

it was said that it has latex content. Also considering the sticky nature of latex,

using it in effectively binding materials is a significant study. The raw materials in

making standard whiteware plastic masses (clay, flint and feldspar) will be used

in the study. The information about the ceramic binder will serve as a reference in

determining the effectiveness of the jackfruit peeling as binder.

The knowledge obtained about the Shrinkage Limit and Modulus of

Rupture will be useful in determining each of them accurately. The Loss on

Ignition test will also be useful in determining the feasibility of Jackfruit pulp as

an alternative ceramic binder.

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Previous studies have used similar materials like marang pulp in producing

binder. Some studies have already used jackfruit peeling as a binder to different

materials such as leatherette which is mentioned previously. However, the

utilization of jackfruit peeling as a ceramic binder (which is the goal of this

present study) is a new study in providing an alternative binder that is also

comparable and similar to the commercial binders or even more effective and

efficient.

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CHAPTER III

METHODOLOGY

A. Research Design

Complete Randomized Design will be used in this study. The

experimental subjects are homogenous since we are only going to use one kind of

standard whiteware plastic mass powder. Each of the experimental subjects will

be randomly distributed to each of the two treatments of the study. The

preparation of the binder (jackfruit pulp) will be made at the researchers’ house

and the experimentation of that binder will be conducted at the College of

Engineering (COE) laboratory, MSU-Iligan Institute of Technology, Iligan City.

B. Materials and Equipments

Materials:

Jackfruit peeling (raw material to alternative binder)

Standard Whiteware Plastic Mass Powder

Spatula

Glass Panel

Tap Water

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Strainer

Graduated Cylinder

Measuring Cups

Containers

Beakers

Rectangular Molder

Equiments:

Blender

Analytical Balance

Weighing Scale

C. Experimental Set-up

Table 2 Experimental Set-up

Components Treatment A

(Jackfruit Pulp as Binder)

Treatment B

(Jackfruit Pulp as Binder)

Jackfruit Pulp (g) 700g 700g

Water (mL) 900mL 900mL

Plastic mass (g) 1500g 1500g

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D. Experimental Procedure

Preparation of the Jackfruit Pulp as a Binder

Jackfruit peelings which are fresh and new including the spines and

ragging will be utilized. The peelings will be ground using the blender and sooner

or later, an amount of water will be added gradually to form a paste from the

jackfruit peeling. To obtain the size of the small particles, it will be strained and

preserved in a plastic bottle. Then it will be stored in the refrigerator, ready to be

used as a binder to the plastic mass.

Preparation of Plastic Mass

A volcano will be formed from the Standard Whiteware Plastic Mass

powder. For the treatment using jackfruit pulp as binder, jackfruit pulp will be

gradually added to the volcano until the mixture hardens (clay-like state). Same

will be done using water only as binder. Treatment A & C will be made earlier

than treatment B & D since we are aiming to came up with an aged plastic mass.

Drying Shrinkage

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Dry Shrinkage is the shrinkage due to drying only. It is simply the percent

change in length between wet and dry. As clay dries, the removal of inter-particle

water causes the mass to tighten up and pack together resulting in shrinkage.

Variation in dry shrinkage is an indicator of changes in plasticity.

Dry Shrinkage differs from Firing Shrinkage in that the former is based on

the initial length of the test bar and the latter is based on the dry length (Hansen,

2003).

Twenty-five trials will be made for each of the treatment. The plastic mass will

be formed into a rectangular bar using a rectangular molder. The initial length of

the rectangular bar will be measured (L0), then, the rectangular plastic mass will

be dried using an oven. The length will be measured again (Lf).

Percent of shrinkage will be measured to determine the drying shrinkage.

To calculate the percent of shrinkage, the length after drying will be subtracted

from the initial length divided by the initial length and multiplied by 100 (as

shown in the formula below).

Drying shrinkage % = L0−Lf

L0 x 100

Where

L0 is the initial length of the test bar and

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Lf is the length of the oven- dried specimen

Firing Shrinkage

Firing Shrinkage is the amount of shrinkage during firing. As a clay fires,

it shrinks and particles continue to pack together. At some point, they begin to

break down and react with each other, fluxes begin to melt and flow, and mineral

grains seed the development of more stable forms.

The firing shrinkage is an indication of the degree to which the complex

maturing process has proceeded (Hansen 2003). Twenty trials will be made for

each of the treatment. The initial length of the rectangular bar obtained after the

determination of the drying shrinkage will be measured (F0), then, the rectangular

bar will be sintered (fired). The length of the fired rectangular bar will be

measured again (Ff). Percent of shrinkage will be calculated to determine the

firing shrinkage of the rectangular bar. To calculate the percent of shrinkage, the

length after firing will be subtracted from the initial length divided by the initial

length and multiplied by 100 (as shown in the formula below).

Firing shrinkage % = F0−F f

F0 x 100

Where

Fo is the length of the oven- dry specimen and

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Ff is the length of the fired specimen

Loss on Ignition Test

To determine the LOI of the rectangular bar, its initial weight (oven-

dried) will be measured first (W0). It will then be fired/sintered and then, the

weight will be measured again (Wf) and the loss on ignition will be determined by

the percent of weight lost on ignition. The loss on ignition will be calculated

numerically by the formula,

% LOI = W 0−WfW 0 x 100

Modulus of Rupture Determination

The rectangular bar will be placed above two supporting blocks. The

length and height of the rectangular bar will be measured (L and H, respectively).

Distance between the supporting blocks will also be measured (D), then, force

will be applied at the center of the rectangular bar using different weights/loads.

The total force applied the time the rectangular bar breaks apart will be measured

(F).

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L = Length of the rectangular bar

D = distance between the supporting blocks

The Modulus of Rupture (M) will then be calculated by the

formula,

M = 3 FD2 L H2

Preparation of Test bars

Needed materials were gathered before molding of test bars was started.

A small amount of oil was poured into a clean molder. This was warranted to

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F = Applied Force

H = height of the rectangular bar

facilitate the making of the test bar as it will just slide and will not deform (Alip

2007).

E. Data Gathering (Tables)

Table 3 Jackfruit Pulp as Binder (Shrinkage Test)

Trials

Initial Length

Oven-Dried Bar Length

Fired Bar Length

% dry shrinkage

%fired shrinkage

T1

T2

.

.

.

T25

Table 4 Water as Binder (Shrinkage Test)

Trials

Initial Length

Oven-Dried Bar Length

Fired Bar Length

% dry shrinkage

%fired shrinkage

T1

T2

.

.

.

T25

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Table 5 Jackfruit Pulp as Binder (Loss on Ignition Test)

Trials

Oven-Dried Bar Weight Fired Bar Weight % Loss on Ignition

T1

T2

.

.

.

T25

Table 6 Water as Binder (Loss on Ignition Test)

Trials

Oven-Dried Bar Weight Fired Bar Weight % Loss on Ignition

T1

T2

.

.

.

T25

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Table 7 Jackfruit Pulp as Binder (Modulus of Rupture)

Trials

Maximum Applied Force before rupture

Distance between supports

Height Length Modulus of Rupture

T1

T2

.

.

.

T25

Table 8 Water as Binder (Modulus of Rupture)

Trials

Maximum Applied Force before rupture

Distance between supports

Height Length Modulus of Rupture

T1

T2

.

.

.

T25

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F. Statistical Tools for Data Analysis

T-test will be used to compare the two treatments (Jackfruit pulp and

water as binder, separately) in regards with the shrinkage, loss on ignition and

modulus of rupture of the plastic mass formulation made using the said binders.

G. Procedure Flow Charts

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350 g of Jackfruit pulp and 450 ml water.

350 g of Jackfruit pulp and 450 ml water.

350 g of Jackfruit pulp and 450 ml water.

350 g of Jackfruit pulp and 450 ml water.

Ground (Blender)

4800 ml of Binder(Approximate Result)

Strained (Strainer)

2500 ml jackfruit pulp (ready for use)

Figure 1.1 Preparation of Jackfruit Pulp as Binder

Figure 1.2 Experimental Methodology

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Formation the Plastic Masses using two different treatments. (Water and jackfruit

pulp as binders)

Firing and Drying Shrinkage Determination of plastic masses

acquired from two different treatments.LOI test to determine the Loss on

Ignition of the Plastic masses acquired from two different treatments.

Modulus of Rupture Determination of the plastic masses acquired from two

different treatments.

Analysis of Data Variance using T-Test