Particleboards were developed by replacing a part of wood with various biomass residues, including coffee bean husks, spent coffee grounds, thistle, Sideritis and dead leaves of Posidonia oceanica. These materials were analysed to determine their physicochemical properties like the moisture content, pH, and buffer capacity, using standard laboratory techniques, while thermogravimetric analysis (TGA), Fourier-transform infrared spectroscopy (FTIR), and X-ray diffraction (XRD) were also used for their further characterisation. The results revealed that all biomasses contained cellulose, hemicellulose, and lignin in varying proportions, along with differing degrees of crystallinity. To produce particleboards, the biomasses were bonded using two types of adhesives: (a) conventional urea-formaldehyde resin (UF) and (b) polymeric 4,4′-methylene diphenyl isocyanate (pMDI). Laboratory-scale, single-layer particleboards were manufactured simulating industrial production practices. These panels were evaluated for their mechanical and physical properties according to European standards. The findings showed a general reduction in mechanical performance when compared to conventional wood-based panels. However, panels made with coffee grounds and Posidonia showed improved resistance to thickness swelling after 24 h in water at 20 °C. Additionally, all experimental panels exhibited lower formaldehyde content than wood-based reference panels. This study demonstrated the feasibility of upcycling biomass residues as a sustainable alternative to virgin wood in the production of particleboard, providing a resource-efficient solution for specific interior applications within a circular economy framework.

This study investigated the use of non-formaldehyde binders in the production of plywood panels, focusing on mixtures containing 70% poly 4,4’-methylene diphenyl isocyanate (pMDI) and 30% soy flour (SF), along with blends of soy flour and agricultural residues (olive by-products—with and without extraction of their bioactive ingredients—and defatted hemp seeds). The basic properties of these biomaterials, such as moisture content, pH, and buffering capacity, were determined with laboratory analysis. Adhesive mixtures were characterized using attenuated total reflectance Fourier transform infrared spectroscopy (ATR-FTIR) and thermogravimetric analysis (TGA). The adhesive’s bonding ability was evaluated by manufacturing plywood panels on a laboratory scale, simulating industrial practices. The glue lines were visually inspected with a stereomicroscope. Micro-ATR-FTIR study of the cross-sections of plywood panels showed the full consumption of isocyanate groups indicating effective curing of the adhesive. Mixtures containing olive residues, particularly olive skin and stones, showed improved thermal stability in the TGA study. The mechanical properties of the plywood panels were assessed with three-point bending tests, while their shear strength and wood failure performance were tested according to the European standards used in the relevant industry (EN 314.1:2004 and EN 314.2:1993). In terms of flexural properties, the adhesive with non-extracted (NE) residual olive skin (ROS) showed the highest flexural strength of around 17 MPa and a flexural modulus of 650 MPa. The formulations containing extracted materials from hemp seeds (HSs) and residual olive skin (ROS) showed the best overall performance with wood failure values of 85% and 75% after the most severe cyclic test (EN314.1:2004-Pretreatment 5.1.3). Overall, the results showed that binders prepared with residual olive skin and defatted hemp seeds have promising performance and can be used in the manufacture of plywood panels.

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.