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Hemp (Cannabis sativa L.) is increasingly valued not only for its fibers and seeds but also for essential oils derived from floral by-products. This study investigates the extraction of essential oils from three hemp floral varieties, Sour Space Candy, Suver Haze 3N, and Pinewalker 3N using hydrodistillation, a widely accepted and efficient method for isolating volatile compounds. The chemical composition and quantification of key volatiles, including α-pinene, β-myrcene, α-humulene, and α-terpineol, were analyzed using gas chromatography–mass spectrometry (GC–MS). In addition to oil extraction, the residual spent biomass was repurposed into pulp fibers using the soda pulping process. Fiber properties such as freeness, viscosity, kappa number, and fiber length were evaluated for papermaking applications. The essential oil yield ranged from 1.24% to 1.86% (w/w), and the spent fiber yield ranged from 37.07% to 55.23%. Handsheets prepared from blends of spent fibers and hemp hurd fibers exhibited tensile indices ranging from 21.87 to 34.98 N·m/g. This dual-valorization approach enhances the economic and environmental value of hemp cultivation, supports sustainable material development, and contributes to the broader adoption of bio-based alternatives.

A key challenge for the paper industry in adopting nanocellulose materials is finding the right balance between production costs and the benefits for specific paper grades, given the industry’s variety of products and processes. This study developed the first model to evaluate changes in steam consumption and other process parameters on a paper machine when incorporating lignin-containing micro- and nano-fibrillated cellulose (LMNFC) as a dry-strength additive, as well as its economic effects. Significant operational differences were observed in steam consumption, dissolved solids in the sewer stream, and production rates when implementing LMNFC in different scenarios. Using the assumption that reductions in basis weight frees up enough drying capacity to offset the additional drying requirements of LMNFC, this led to a 15% reduction in manufacturing costs while maintaining paper strength. A capital payback period of five years was estimated for LMNFC production, with a minimum selling price of $243 per ton. It is important to evaluate both process dynamics and dual cost metrics (cost per ton and cost per area), when analyzing the impact of LMNFC on linerboard production. While LMNFC increases the cost per ton, the lower cost per MSF underscores its material efficiency and economic benefits, particularly for lightweight grades.

Molded cellulosic pulp products provide eco-friendly alternatives to various petroleum-based packaging systems. They have a long history of reliable usage for such applications as egg trays and the shipping of fruits. They have recently become increasingly used for the packaging of electronics, wine bottles, and specialty items. Molded pulp products are especially used in applications requiring cushioning ability, as well as when it is important to match the shapes of the packed items. Their main component, cellulosic fibers from virgin or recycled wood fibers, as well as various nonwood fibers, can reduce society’s dependence on plastics, including expanded polystyrene. However, the dewatering of molded pulp tends to be slow, and the subsequent evaporation of water is energy-intensive. The article reviews strategies to increase production rates and to lower energy consumption. In addition, by applying chemical treatments and processing approaches, there are opportunities to achieve desired end-use properties, such as grease resistance. New manufacturing strategies, including rapid prototyping and advances in tooling, provide opportunities for more efficient form factors and more effective packaging in the future.

Cellulose nanocrystals (CNCs) were surface-modified using immobilized lipase (Novozyme 435) to catalyze the formation of laurate ester groups on the CNC surface and thus facilitate homogeneous dispersion within a poly(lactic acid) (PLA) matrix. Results of dynamic contact angle measurement revealed that the modified CNCs (CNC-LAA) presented greater hydrophobicity than their CNC controls. FT-IR, 13C-NMR, XRD, and TGA were used to characterize the structure and stability of the CNCs before and after modification. PLA reinforced with the modified CNCs were prepared, and the effect on mechanical properties was studied. SEM micrographs suggested uniform dispersion of modified CNCs throughout the PLA matrix at a maximum 1 wt% loading, which was found to be the optimal loading level. The CNC-LAA were able to achieve a 0.4 maximum degree of substitution. DSC indicated enhanced crystallization of PLA chains due to the inclusion of CNC-LAA, indicating that the nanofillers behaved as nucleating agents and also revealed improved compatibility. Tensile strength tests showed slightly improved mechanical properties for breaking strength and elongation at breakage.

As a way to reduce microplastics or nano-plastics in the ocean, it is of interest to develop biodegradable paper-based drinking straws to replace non-degradable plastic drinking straws. Primary questions to be addressed include how to design suitable coatings for paper drinking straws. Such coatings not only need to resist water. In addition, consumers have high expectations for the strength of a drinking straw. It is proposed here to replace non-biodegradable polypropylene, which is presently the main component of straws, with biodegradable and hydrophobic coating components via an entropy-driven approach. It is further proposed to develop colored paper-based drinking straws with cellulose nematic liquid crystal photonic pigments as a way to make the product stand out visibly, while at the same time mediating the usage of toxic chemical pigments.

This study introduces an innovative approach for developing high strength-high softness recycled fibers through soft mechanical treatment. Recycled fibers from old corrugated containers were treated using a homogenizer, a refiner, and in tandem. The recycled fibers and tissue paper sheets after the treatments were evaluated for the effect on critical properties such as fiber morphologies, freeness, water retention, hard-to-remove water, bulk, softness, tensile strength, and water absorption. High softness and tensile strength were achieved with mechanical treatment by utilizing a homogenizer alone or in tandem with a refiner. Overall, the homogenized recycled fibers and tissue paper sheets provided higher bulk, water absorption, and tensile strength while maintaining the softness and drainage (freeness) behavior similar to unrefined paper sheets. It was found that homogenization helps in deflocculating the recycled fibers without negatively affecting the fiber quality, such as fines generation.Graphic abstract

Hemicelluloses, the second most abundant class of biopolymers, have emerged as an immense renewable resource of biopolymers that are recognized as currently being underutilized. Carboxymethyl carbohydrates are valuable products for thickeners, viscosity control, food additive and others. Hemicellulose isolated from poplar was converted to carboxymethyl hemicellulose using sodium chloroacetate (SCA) and sodium hydroxide (NaOH). The significance of the effects of carboxymethylation conditions in an 80% ethanol/water medium on the degree of substitution (DS) and reaction efficiency (RE) was evaluated using a definitive screening design model. There was strong evidence that the dosage of SCA and NaOH, and temperature have a significant effect on DS. A significant interaction between SCA and NaOH was also statistically confirmed. The RE resulting from the ethanol/water medium was lower than 50%. A higher RE of 72% with a DS 1.08 was achieved in a 90% tert-butyl alcohol/water medium, which was conducted at 85 °C with 120 min, 1.5 mol/mol anhydroxylose unit (AXU) of NaOH and 1.5 mol/mol AXU of SCA. The potential of using hemicellulose and carboxymethyl hemicellulose as materials to produce water-soluble films was evaluated. Due to the increased water solubility, the processing of carboxymethyl hemicellulose in water and the production of films were more facile than with unmodified hemicellulose. All of the films demonstrated significant oxygen barrier characteristics, with low oxygen permeability ranging from 0.28 to 0.55 cm3 µm/(m2 d kPa). The films did not display effective water vapor barrier characteristics, with high water vapor permeability ranging from 4.8 to 6.5 g mm/(m2 d kPa). Carboxymethylation of HC decreased the tensile strength, increased the elongation at break, and decreased the water vapor and oxygen barrier properties of the produced films. Both hemicellulose and carboxymethyl hemicellulose films could offer a bio-based and biodegradable alternative to existing synthetic oxygen barrier materials. The hemicellulose and carboxymethyl hemicellulose materials might be exploited in water-soluble films, washable fruit coating or used in composites or multilayer films in conjunction with hydrophobic layers.Graphic abstract

Recent advances in artificial intelligence (AI) offer significant opportunities to drive industrial transformation by addressing growing societal demands for products, techno-economic efficiency, and reduced carbon footprints. This review presents a structured framework for building transparent, scalable, and sustainable AI-driven infrastructures spanning conceptualization to commercialization for materials discovery and advanced manufacturing. The framework traces the evolution of materials development from empirical approaches toward integrated AI-enabled platforms, emphasizing open-source tools that unify data acquisition, modeling, simulation, and deployment to democratize access, foster collaboration, and enhance reproducibility. Key enabling components include self-driving laboratories for real-time optimization, advanced computational approaches for high-fidelity data, and blockchain-based mechanisms for secure data sharing, provenance, and supply-chain traceability. The review further discusses the importance of machine learning for materials property prediction, synthesis and process optimization, together with scalable cloud–edge architectures that improve efficiency and reduce latency. Emphasis is placed on lifecycle-aware design, techno-economic analysis, and ethical AI principles to align industrial development with global sustainability goals. Recent advances in AI present opportunities to transform industries by meeting demands for efficiency and sustainability. Here, the authors propose a framework for AI-driven infrastructures in materials discovery and manufacturing, highlighting open-source tools and scalable architectures to democratize access, enhance collaboration, and align with global sustainability goals.

The production of industrial hemp (Cannabis sativa L.) has expanded recently in the US. Limited agronomic knowledge and supply chain issues, however, stemming from a long-standing cultivation ban, pose a barrier to continued market expansion of hemp, which leads to the import of most hemp products. This review examines the most recent cultivation methods, fertilizer and nutrient requirements, soil management practices, environmental parameters, and post-harvest processing methods, particularly in the context of environmental benefits such as soil phytoremediation and CO2 sequestration. Details of the valorization of hemp biomass into sustainable products, such as fibers, papers, packaging, textiles, biocomposites, biofuels, biochar, and bioplastics, along with current limitations and scope for improvements, are explored. Finally, an overall summary of the life cycle and techno-economic analysis aimed at optimizing their environmental performance and economic feasibility are discussed with a focus on intersection with the growing circular economy paradigm.

Background The pulp and paper industry is under increasing pressure to adopt sustainable solutions that address its substantial energy consumption and environmental impact. One of the most energy-intensive operations is the thermal drying, which presents significant opportunities for efficiency improvements. This study evaluates a cell-free mild enzyme pretreatment, utilizing a cocktail of cellulases and xylanases, combined with cationic starch, to enhance dewatering efficiency and improve paper strength utilizing bleached hardwood pulp fibers. Life cycle and economic analysis were also conducted to quantify the environmental impact and economic benefits, with a particular focus on direct greenhouse gas emissions. Enhanced water removal during pressing can significantly reduce energy consumption during thermal drying, facilitating the decarbonization of the paper industry. Results The cell-free enzyme pretreatment, applied with mild refining and cationic starch, achieved significant improvements in dewatering efficiency and paper strength. The treatment led to an 11% point increase in solids and a 25% improvement in tensile strength. Morphological analyses revealed no changes in fiber length and width; however, reductions in kink and curl indexes indicated enhanced fiber flexibility and bonding potential. Furthermore, the enzyme–starch combination decreased water retention value by 27%, including substantial reductions in bound and hard-to-remove water content. Environmental assessments estimated a 12% reduction in global warming potential (GWP), with the technology yielding net savings of $11.29 per air-dried ton of paper through reduced natural gas consumption. Conclusions This study demonstrates the technical feasibility and economic viability of incorporating enzyme and cationic starch treatments into papermaking. The treatment improves paper quality while reducing energy consumption, costs, and carbon emissions. These findings support the broader adoption of enzyme-based innovations for sustainable manufacturing, aligning with decarbonization goals and industry demands for greater efficiency. The results highlight a promising avenue for achieving significant environmental and economic benefits in the pulp and paper sector. Graphical Abstract