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<p>Recycled fibers have become indispensable in sustainable paper manufacturing, yet repeated recycling triggers irreversible fiber hornification—a structural deterioration marked by impaired water retention, diminished swelling capacity, and compromised mechanical integrity that progressively limits fiber reuse potential. This study employed size-fractionated secondary fibers treated at a fixed beating degree (45°SR) to systematically investigate the morphological evolution and mechanical degradation of the different sizes of fibers during recycling. Critical degradation thresholds were identified to inform targeted regeneration strategies. By identifying critical degradation thresholds during recycling, we applied microwave expansion to selectively enhance fiber quality, with structural modifications characterized using FTIR, XRD, and SEM analyses. In the recycling process of the two fibers, the non-recycled paper mechanical properties are the best, tensile strength was W1R0 (Long fibers: 0–30 mesh, 0 times in recycling): 5.09&#xa0;kN/m and W3R0 (short fibers: 0–30 mesh, 0 times in recycling): 3.25&#xa0;kN/m, and long fibers into the mechanical strength of the paper are significantly stronger than the short fibers, but the short fibers have a slower increase in keratinization degree and better water retention. Microwave puffing of the two fibers after its mechanical properties have risen fiber water retention value increased by 4.68% and 15.89%, respectively; XRD shows that the W1 and W3 crystallinity decreased by 21.50% and 8.48%, respectively; SEM images can also be seen after the expansion of the fiber is fuller. These findings provide critical insights for optimizing secondary fiber processing protocols to counteract hornification-induced degradation.</p> Graphical Abstract <p></p>

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Decay of fibers of different sizes during reuse and effect of microwave puffing

  • 期刊论文

  • 发表日期：

    2025年7月7日

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  • Wenshuo Li,
  • Jizhen Huang,
  • Chunting Li,
  • Jianquan Hu,
  • LiangLiang An,
  • Yuxin Liu

摘要

Recycled fibers have become indispensable in sustainable paper manufacturing, yet repeated recycling triggers irreversible fiber hornification—a structural deterioration marked by impaired water retention, diminished swelling capacity, and compromised mechanical integrity that progressively limits fiber reuse potential. This study employed size-fractionated secondary fibers treated at a fixed beating degree (45°SR) to systematically investigate the morphological evolution and mechanical degradation of the different sizes of fibers during recycling. Critical degradation thresholds were identified to inform targeted regeneration strategies. By identifying critical degradation thresholds during recycling, we applied microwave expansion to selectively enhance fiber quality, with structural modifications characterized using FTIR, XRD, and SEM analyses. In the recycling process of the two fibers, the non-recycled paper mechanical properties are the best, tensile strength was W1R0 (Long fibers: 0–30 mesh, 0 times in recycling): 5.09 kN/m and W3R0 (short fibers: 0–30 mesh, 0 times in recycling): 3.25 kN/m, and long fibers into the mechanical strength of the paper are significantly stronger than the short fibers, but the short fibers have a slower increase in keratinization degree and better water retention. Microwave puffing of the two fibers after its mechanical properties have risen fiber water retention value increased by 4.68% and 15.89%, respectively; XRD shows that the W1 and W3 crystallinity decreased by 21.50% and 8.48%, respectively; SEM images can also be seen after the expansion of the fiber is fuller. These findings provide critical insights for optimizing secondary fiber processing protocols to counteract hornification-induced degradation.

Graphical Abstract