This research addresses the current need for sustainable solutions in the construction and furniture industries, with a focus on environmentally friendly particleboard. Particleboards were made from a mixture of virgin wood chips and hemp shives, which were then mechanically recycled and used to make new lightweight particleboards. Phenol–formaldehyde resin with 25% w/w phenol replacement by soybean flour (PFS) was used as the binder for the lignocellulosic materials. Laboratory analyses determined the resin properties, and FTIR confirmed the structure of the experimental PFS resin. The thermal properties of all the resins were evaluated using thermogravimetric analysis (TGA). The panels were manufactured using industrial simulation and tested for mechanical and physical properties in accordance with European standards. The FTIR study confirmed good adhesion, and the TGA showed improved thermal stability for the recycled biomass panels compared to virgin biomass panels. The study concludes that lightweight particleboards can be successfully produced from recycled hemp shive-based panels, providing a sustainable alternative to traditional materials in the construction industry.

Bio-based phenolic resins were developed with phenol substitution levels of 20% and 40% with crude extracts obtained from spent coffee grounds. The experimental resins were characterized in terms of their physical, chemical and bonding properties and exhibited the typical property levels of Phenol-Formaldehyde-type resins. Plywood panels were produced bonded with the novel experimental resins, exhibiting satisfactory performance, comparable to the reference panels in terms of both shear strength and wood failure, based on the requirements of the European standards. The results demonstrate the potential of using biomass-derived compounds as substitutes for petrochemical phenol in the production of wood adhesives, thereby increasing the bio-based content of the wood panel composites produced with them and improving their sustainability.