Composite material based on cow dung as a craft product and its manufacturing process

Abstract

This invention encompasses a composite material based on cow dung as a craft product and its manufacturing process. With the global issue of environmental pollution increasingly impacting social aspects of society, this invention addresses one such issue through the processing of waste materials and community-based production methods. Using ethnographic and participatory design approaches, cow dung waste is initially transformed into various functional products that align with the daily activities of the local community. In subsequent production stages, the development of these products into crafts is expected to significantly address waste, environmental, and social issues in Indonesia, considering the characteristics of its communities. Furthermore, this invention aims to contribute to the structured development of craft production from the smallest community groups to broader scopes. The vision for this cow dung waste production is intended as an effort to empower grassroots businesses that are local, sustainable, and closely related to the daily problems of the residents. This composite material consists of cow dung, an adhesive mixture of polyvinyl acetate and water, a filler material of calcium carbonate, pigments both organic and inorganic, and clove and pine oils.

Description

[0001] Description

[0002] COMPOSITE MATERIAL BASED ON COW DUNG AS A CRAFT PRODUCT AND

[0003] ITS MANUFACTURING PROCESS

[0004] Field of the Invention

[0005] This invention relates to a composite material based on cow dung as a craft product and its manufacturing process . More speci fically, this invention concerns a material made from cow dung waste , particularly the processing method, production process , and molding into craft products that can be mass-produced with flexible application and high consistency in quality .

[0006] Invention Background

[0007] The problem of methane gas production generated from animal dung and general waste is relatively high and has become a pollution issue in Indonesia . The largest methane emissions in Indonesia come from the agricultural sector . Indonesia has extensive farmland and rice fields , with the f ourth-largest population in the world ( Central Statistics Body 2022 ) . Regarding methane gas from waste and trash, data from the Ministry of Environment and Forestry in 2021 recorded that the volume of waste in general in Indonesia, covering 154 regencies / cities , reached 18 . 2 million tons per year . This means that well-managed waste amounts to only 13 . 2 million tons per year or 72 . 95% . The large volume of waste is directly proportional to the level of methane gas emissions produced through the decomposition process , one of the factors being the disposal of animal dung in the livestock sector . The development of the agricultural and livestock sectors is progressing in various regions of Indonesia . In this regard, the focus of this invention is in West Java, particularly in the Lembang area, which is a pioneer in residential-based livestock farming in West Java . As the target study area, Kampung Bukatanah is located in Langensari Village , Lembang District , Bandung, and coexists with cow dung disposed through the existing drainage system around residential areas . Alongside the decreasing agricultural land and vegetable farmers in Langensari , the cycle and ecosystem of cow dung, which is usually channeled into agricultural land as organic fertili zer, have become unbalanced . As a result , the abundance of untreated cow dung in the environment around Kampung Bukatanah poses a potential threat to soil , water, and air pollution, which can impact sanitation levels and the community ' s quality of li fe .

[0008] In line with the continuous advancement of science and technology, innovations and techniques for processing cow dung have also progressed rapidly . Through ethnographic approaches and participatory design, there has been a two- way discussion between researchers and the residents of Bukatanah to find solutions to environmental issues in Kampung Bukatanah . The outcome of these environmental problem-solving ef forts involves experimenting with processing animal waste , speci fically cow dung, which can be used as a main material for producing craft products that has a high market potential . Using the latest knowledge related to chemical processes and small-scale production, composite materials based on cow dung are processed into craft products . This aligns with the primary focus of the residents of Kampung Bukatanah in addressing issues related to cow dung waste that pollutes their environment . The invention of composite materials made from cow dung, as disclosed in patent number CN107232949A titled Novel appli ca ti ons of cow dung and incense products containing cow dung, reveals that the composite from cow dung can be used in incense products . However, the invention still has a drawback : the natural drying process of the composite takes three to five years .

[0009] The invention was also found in a research proj ect conducted by Aparna Ra agopal . Through the Down To Earth website , under the title She sell s cow dung products but not milk to save India ' s desi cows, it was revealed that composite from cow dung has been used as a substitute material for firewood, flower pots , and Indian deity sculptures among the products of her craftsmanship . However, this invention has a weaknes s in its production process and method, which still relies on manual drying and molding techniques .

[0010] The invention related to the utili zation of cow dung composite was also disclosed in a collaborative proj ect involving an entrepreneur and three mechanical engineering academics from India . Through The Tribune India website , in an article titled Roh tak engineering teachers , entrepreneur get pa tent for cow dung composi te, it was revealed that the composite material from cow dung was used to create Gaucrete Bricks , which are bricks made by mixing cow dung, clay, and lime . This invention has a weakness in the form of its drying method, which still relies on sunlight . Consequently, the production time required for molding is longer .

[0011] Furthermore , this invention aims to address existing issues and complement previous inventions ' shortcomings by renewing cow dung ' s method and processing according to modern industrial standards . This invention aims to provide a composite material based on cow dung for producing craft products and its manufacturing process . This invention pertains to a material made from cow dung waste , particularly its processing method, process , and molding into craft products that can be mass-produced with flexible application and high-quality consistency . This material originates from readily available and inexpensive waste sources , contributing to environmental sustainability . The production method is easily scalable with consistent quality and utili zes cost-ef fective , user- friendly technology applicable to the general public .

[0012] This invention also aims to streamline craftsmanship through reverse molding techniques assisted by 3D printing . This process can yield final products with more appealing and accurate shapes at a faster production rate compared to conventional techniques .

[0013] Summary of The Invention

[0014] According to this invention, a composite material is provided using cow dung as a base for craftsmanship products , with the following weight / volume percentage composition of each component in the total mixture : cow dung 40-45% , binder 25-30% , filler material 15-20% , pigment 2- 6% , and oil 2- 6% .

[0015] The manufacturing process of the composite material consists of the following stages : mixing and stirring cow dung with water, and extracting cellulose and hemicellulose fibers by pressing them using a hydraulic press machine . The extracted cellulose fibers account for 10- 15% of the total weight of cow dung . The primary function of these cellulose and hemicellulose fibers is to provide structural support to the composite material . Next , the process involves bleaching the fibers using hydrogen peroxide , drying them using a dehydrator, grinding the fibers using a disk mill machine , and mixing the cellulose and hemicellulose fibers with binder, filler material , pigment , and oil by kneading until the mixture is evenly distributed . Then, the composite dough is molded into molds , dried using a dehydrator once formed, removed from the molds after drying, shaped and smoothed using sanding, and coated entirely with an acrylic-based coating on the product surface .

[0016] Brief Description of the Figure

[0017] Figure 1 depicts the flowchart of the process and techniques for manufacturing the composite material according to this invention .

[0018] Detailed Description of the Invention

[0019] This invention provides a method for processing composite material based on cow dung to be used as a main material for making craft product . Cow dung can be def ined as residual food material consumed that is not digested and expelled by herbivorous species of cattle , making a mixture of feces and urine in a ratio of 3 : 1 , primarily consisting of lignin, cellulose , and hemicellulose . Cellulose and hemicellulose are the main components that strengthen the cell walls of plants , allowing this material to be utili zed as fibers to reinforce the structure of composite materials derived from cow dung .

[0020] The processing of the material begins with washing and separating cellulose , hemicellulose , and lignin fibers from the mixed dung, including fats , minerals , and other chemical elements . This process is known as hydrolysis , where the cow dung is mixed with water to break down the chemicals within it , with a ratio of cow dung to water at 1 : 1 . In this invention ' s case , 30 kg of the composite material is mixed with 30 liters of water and stirred consistently using a machine for 10 minutes. Subsequently, the cow dung mixed with water is pressed using a hydraulic press machine. This process is repeated twice to ensure the purity of the cellulose fibers from the cow dung. From this extraction process, an output of 7-10 kg (23%- 30%) is obtained, consisting of a mixture of cellulose, hemicellulose, and lignin fibers.

[0021] Next, the cellulose and hemicellulose fibers are further purified by mixing them with Hydrogen Peroxide (H2O2) . This process aims to separate lignin content and other residue from the dung. The Hydrogen Peroxide used has a purity percentage of 5%, with a total weight of 30 kg used to purify 4 kg of cellulose fibers. The process involves immersing the cellulose and hemicellulose fibers in the H2O2 solution and stirring for 10 minutes. The mixture is then left to stand for 1 week at a temperature of 45°C. Due to the exothermic nature of the process, mixing needs to be gradual, and stirring should be done at a low speed. After the incubation phase of 1 week, the cellulose and hemicellulose fibers are pressed using a hydraulic press machine and dried using a dehydrator at 90°C for 15 hours. The clean cellulose and hemicellulose fibers obtained from this process amount to 4-5 kg. Following this, the dry and clean cellulose and hemicellulose fibers undergo milling using a disk mill machine with a sieve having 1 mm holes. This process aims to standardize particle size to ensure that the resulting composite material is homogeneous. Subsequently, the cellulose and hemicellulose fibers are mixed with polyvinyl acetate (PVAC) adhesive, calcium carbonate (CaCO3) filler, color pigments, and basil oil with the following proportions: cow dung at 40-45%, PVAC adhesive at 25-30% , CaCO3 filler at 15-20% , pigments at 2- 6% , and oil at 2- 6% .

[0022] The mixture is then kneaded until it has a clay-like consistency and is ready to be molded . The molding process is performed by manually applying the composite mixture to the mold . This mold is made of plastic and is created us ing either 3D printing or inj ection molding methods . After the mixture is evenly applied to the mold, then the mold is dried using a dehydrator at 50 ° C for 5- 10 hours . Once dried, the 3D-printed mold is removed, and the product is sanded to smooth the surface . The sanding process is carried out using an orbital sander, a lathe , and a sandblasting machine . Finally, the entire surface of the product is coated with a water-based acrylic sealant to close the composite pores , protect against moisture , prevent color fading, and enhance the product ' s aesthetics .

[0023] The extraction process of cellulose and hemicellulose from cow dung takes one week, while the molding process to create the product takes 1 -2 hours . This timeframe allows for quick and ef fective mass manufacturing, ensuring consistent design results due to the casting and molding techniques used .

[0024] This invention is expected to contribute to solving environmental and social sustainability issues by creating materials and production methods that are more responsible . Indonesia, as a country with abundant paddy fields and human resources , should pioneer the development of various research initiatives and applications of materials that can drive the economy and improve environmental quality .

Claims

Claims1. A composite material based on cow dung as a craft product, consisting of a mixture of the following components : cow dung, serving as the primary material; an adhesive composed of a mixture of polyvinyl acetate and water in a 1:1 ratio, functioning to bond the cow dung; a filler material in the form of calcium carbonate, serving to enhance the mechanical properties to harden the composite and reduce mold shrinkage;Pigments, both organic and inorganic, used to add color to the product;Clove and pine oils, serving as preservatives to prevent mold and reduce odor from the dung.

2. A composite material as claimed in claim 1, wherein the weight / volume percentage composition of each component relative to the overall mixture is as follows: cow dung at 40-45%;PVAC adhesive at 25-30%;CaCO3 filler at 15-20%; pigments at 2-6%; oils at 2-6%.

3. A composite material as claimed in claims 1 and 2, wherein the cow dung used contains cellulose and hemicellulose .

4. A composite material as claimed in claims 1 and 2, wherein the organic pigments used are divided into two types: natural organic pigments sourced from plant extracts such as coffee, tea, turmeric, and spinach, and synthetic organic pigments of the azo type, while the inorganic pigments used are derived from iron oxide.

5. A process for manufacturing the composite material as claimed in claims 1 to 4, comprising the following steps : a. mixing and stirring cow dung with water; b. extracting cellulose and hemicellulose fibers by pressing with a hydraulic press; c. whitening the cellulose and hemicellulose fibers using hydrogen peroxide; d. drying the cellulose and hemicellulose fibers using a dehydrator; e. grinding the cellulose and hemicellulose fibers using a disk mill; f. kneading the cellulose and hemicellulose fibers with the adhesive, filler material, pigments, and oils until the dough is uniformly mixed; g. molding the composite dough into molds; h. drying the formed composite using a dehydrator; i. releasing the dried composite dough from the mold; j . shaping and smoothing the surface by sanding; k. coating the entire surface of the product with an acrylic-based coating.

6. A process for manufacturing the composite material as claimed in claim 5, wherein the mixing ratio of cow dung and water is 1:1, with stirring for 10 minutes consistently .

7. A process for manufacturing the composite material as claimed in claim 5, wherein the whitening process of cellulose and hemicellulose fibers using hydrogen peroxide involves stirring for 10 minutes and then letting the mixture stand for 1 week at a temperature of 45°C.

8. A process for manufacturing the composite material as claimed in claim 5, wherein the drying process ofcellulose and hemicellulose fibers using a dehydrator is conducted at 90°C for 15 hours.

9. A process for manufacturing the composite material as claimed in claim 5, wherein the drying process of the formed composite using a dehydrator is conducted at50°C for 5-10 hours.

10. A process for manufacturing the composite material as claimed in claim 5, wherein the sanding process is performed using an orbital sander, lathe, and sandblasting machine.

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