Pilot-Scale Evaluation and Production Feasibility of Sustainable Antimicrobial Paper from Sugarcane Bagasse

This study examines the production of antimicrobial paper of sugarcane bagasse at the pilot-scales and also evaluates its potential to displace conventional plastic packaging. Early chemical analysis indicated the high cellulose content of SCB (≈45%) was suitable for pulping and paper formation. Pilot-scale experiments showed pulping yields in the 55–70% range under optimized conditions (120–160 °C, 30–90 min), and attributed improved fiber separation and less residual lignin to the established process. To improve their antimicrobial activity and mechanical properties, nanocomposite coatings based on silver nanoparticles (AgNPs,) chitosan-silver (CS-AgNPs), and silver/zinc oxide (Ag/ZnO) were deposited. The bending stiffness (up to 23±3 N/mm), tensile strength (up to 41±3 Nm/g), and folding endurance (up to 47±5 cycles) are vastly superior compared with the data of uncoated samples. Abstract: Antimicrobial testing against E. coli and S. aureus showed significant inhibition zones (maximum 17.0 mm), Ag/ZnO 2% exhibited the best antimicrobial activity. A preliminary cost and energy analysis revealed that significant drivers of cost came from nanoparticle synthesis and drying stages, and energy analysis reported a cumulative energy requirement of 1.3 kWh/kg of paper. Notwithstanding these obstacles, the results underscore the promise of SCB in obtaining high-performance, antimicrobial packaging. To enable large-scale production of this sustainable material, improvements in coating deposition, cost management of nanoparticles, and energy efficiency may facilitate commercial roll out.