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Composites in 25 kg batches were compounded of cellulose nanocrystals (CNC) and thermomechanical pulp (TMP) and shaped into caps at industrial facilities on a pilot-plant scale. Some of the material was also injection molded into plaques to compare the effect of laboratory-scale and pilot-scale compounding of poly(ethylene-co-acrylic acid) (EAA7) and poly(caprolactone) composites reinforced with 10 wt% CNC and TMP. The materials compounded under laboratory-scale conditions showed a different morphology, improved mechanical properties, and a higher viscosity, than the materials compounded on a pilot-scale. In some cases, the rheological properties of the melts indicated the presence of a relatively strong percolating cellulosic network, and the interphase region between the cellulose and the matrix appears to be important for the mechanical performance of the composites. After the compounding on a pilot scale, both the length and width of the pulp fibers was reduced. The TMP provided better reinforcement than the CNC possibly due to the higher aspect ratio.

Composite materials based on an ethylene-acrylic acid (EAA) copolymer and 20 wt% cellulose fibers were compounded by two runs in a twin-screw extruder. The composite material with cellulose fibers (CF) and a reference of unfilled EAA were injection molded into plaques using three different temperature profiles with end zone temperatures of 170°C, 200°C, and 230°C. The injection molded samples were then characterized in terms of their mechanical properties, thermal properties, appearance (color and gloss), and surface topography. The higher processing temperatures resulted in a clear discoloration of the composites, but there was no deterioration in the mechanical performance. The addition of cellulose typically gave a tensile modulus three times higher than that of the unfilled EAA, but the strength and strain at rupture were reduced when fibers were added. The processing temperature had no significant influence on the mechanical properties of the composites. Gloss measurements revealed negligible differences between the samples molded at the different melt temperatures but the surface smoothness was somewhat higher when the melt temperature was increased. In general, addition of the cellulose to the EAA reduced the gloss level and the surface smoothness. POLYM. ENG. SCI., 2019. © 2019 Society of Plastics Engineers.