RESEARCH PROPOSAL

ON
VALORIZATION OF LIME TRIMMING TANNERY SOLID
WASTE FOR THE PRODUCTION OF PAPER

BY
WENDWOSEN EBABU

AKALU TESHOME

DESSIE FETENE

KOMBOLCHA INSTITUTE OF TECHNOLOGY

WOLLO UNIVERSITY

KOMBOLCHA, ETHIOPIA

AUGUST, 2022
 RESEARCHERS PROFILE
S.no Researchers name First degree Second degree
1 Wondwosen Ebabu In Leather Engineering In Leather product
design and
Engineering
2 Aklau Teshome In manufacturing Engineering specialized in Footwear
and leather goods manufacturing
3 Dessie Fetene In manufacturing Engineering specialized in Footwear
and leather goods manufacturing

i
Submitted by:

Wendwosen Ebabu _______________ ______________

Signature date

Akalu Teshome _______________ ______________

Signature date

Dessie Fetene ________________ ___________

Signature date

ii
TABLE OF CONTENTS
RESEARCHERS PROFILE ............................................................................................................ i
LIST OF FIGURES ........................................................................................................................ v
LIST OF TABLES ......................................................................................................................... vi
CHAPTER ONE ............................................................................................................................. 1
INTRODUCTION .......................................................................................................................... 1
1.1 Background of the study ....................................................................................................... 1
1.2. Statement of the problem ..................................................................................................... 2
1.3. Objectives ............................................................................................................................. 3
1.3.1. General objective ........................................................................................................... 3
1.3.2. Specific objectives ......................................................................................................... 3
1.4. Justification .......................................................................................................................... 3
1.5. Benefits and beneficiary of the study ................................................................................... 4
1.5.1. The benefits of the study ............................................................................................... 4
1.5.2. Beneficiary from the study ............................................................................................ 4
1.6. Scope of the study ................................................................................................................ 4
1.7. Facility available .................................................................................................................. 4
1.8. Implications .......................................................................................................................... 4
CHAPTER TWO ............................................................................................................................ 6
2. LITERATURE REVIEW ........................................................................................................... 6
2.1. Leather industry.................................................................................................................... 6
2.2. Leather industry waste ..................................................................................................... 7
2.2.1 Solid waste ...................................................................................................................... 7
2.3. Paper manufacturing ............................................................................................................ 9
2.3.1 Raw material for paper production ............................................................................... 11
2.4. Research gaps analysis ....................................................................................................... 11
CHAPTER THREE ...................................................................................................................... 12
3. MATERIALS AND METHODS .............................................................................................. 12
3.1. Chemicals and Equipment .................................................................................................. 12
3.2. Methods .............................................................................................................................. 12
3.2.1 General working procedures of the research ................................................................ 12

iii
 3.2.2. Phase 1. Extraction of pulp fiber from lime trimming waste ...................................... 13
3.2.3. Phase 2: Paper preparation from pulp fiber ................................................................. 13
3.3. Data collection methods .................................................................................................... 13
3.4. Data analysis methods ........................................................................................................ 14
3.5. Finished paper test evaluation ............................................................................................ 14
CHAPTER FOUR ......................................................................................................................... 15
4. Time schedule and financial plan ............................................................................................. 15
4.1. Time schedule .................................................................................................................... 15
4.2. Financial plan ..................................................................................................................... 16
Reference ...................................................................................................................................... 18

iv
LIST OF FIGURES
Figure 1 Leather industry waste ...................................................................................................... 7
Figure 2. Type of tannery wastes .................................................................................................... 8
Figure 3. General working procedures of the research ................................................................. 12
Figure 4. Extraction of pulp fiber from lime trimming waste....................................................... 13
Figure 5 Paper preparation procedure ........................................................................................... 13

v
LIST OF TABLES
Table 1 Solid waste generated in leather tannery.......................................................................................... 9
Table 2. Chemicals for paper production .................................................................................................... 12
Table 3 Time schedule ................................................................................................................................ 15
Table 4 Financial plans ............................................................................................................................... 16

vi
CHAPTER ONE
INTRODUCTION

1.1 Background of the study

The industrial sector, including tanneries, distilleries, and paper and textile industries, plays an
essential role in the manufacturing of various products to fulfill the needs of society. These
industries continue to emit waste contaminants to the environment during the manufacturing
process (Ławińska et al., 2020). The tannery industry is one of the most polluting industries
considering the generation of a massive amount of liquid and solid waste (Nur-E-Alam et al.,
2020).

Hides and skins, which are leftovers from the meat and meat product manufacturing business, are
typically used by the tanning industry as the primary raw materials for the creation of leather, a
good commercial commodity(Sundar et al., 2011). Ethiopia's primary export is leather, which
contributes significantly to the country's economic prosperity. This is due to the fact that, after
coffee, it earns the second-highest export revenue (Hussien, 2014).
Globally, thousands of items currently use tanning. Use cases for Luxury products made of leather
range in quality from high to low and include bags, cars, and apparel.
to useful products such as saddles, sporting goods, and footwear (Grumiller and Raza, 2019).

Leather industry wastes emit three types of wastes, such as liquid, solid, and gaseous wastes. Solid
leather wastes are generated from tanneries and leather goods industries and include mainly skin
trimmings, chrome shavings, buffing dust, finished leather scraps, etc (Fela et al., 2011). One of
the most resource-and pollution-intensive industries is the leather one. From 1 Mg of raw
materials, 0.25 Mg of leather is produced, requiring 15,000 to 120,000 m3 of water, resulting in 15
to 50 Mg of effluent and 400 to 700 kg of solid waste (Hu et al., 2011).

The leather industry generates large amounts of waste, most of which is burned, causing
environmental pollution (Mohamed and Kassem, 2010). Over time, several methods for reducing
and recycling solid tannery waste have been created, including biogas and biohydrogen
production, biodiesel and briquette production, construction materials, fertilizers, commercial

1
products like adsorbents, animal feeds, proteins, fats, and enzymes, as well as the production of
biodegradable packaging and non-packaging materials (Verma and Sharma, 2022).
If the solid waste produced during tannery processing, which contains many hazardous chemicals,
is not appropriately used or disposed of, it is likely to have a negative impact on the environment
(Sivaram and Barik, 2019).

Tanner's solid waste is used for the raw material for the production of poultry feed (Paul et al.,
2013), for gelatin and glue production (John Sundar et al., 2011, Cabeza et al., 1998, Pati et al.,
2014), generation of biogas energy (Mavrodin et al., 2015), Bricks making (Fathima et al., 2012),
and concrete block (Sivaprakash et al., 2017). Paper is made of interconnected fibers, whether it
is prepared in a sophisticated machine or by the most meticulous, delicate hand techniques. A
variety of materials, including fabric rags, cellulose fibers from plants, and most notably trees, can
be used to make the fibers (de Sola Pool, 1983). Fibrous raw materials for pulp making are divided
into three main categories: wood fibers that constitute about 75% of all the fibrous raw material
supply of pulp mills; reclaimed waste paper, about 20%; and the remaining 5% are nonwood fibers
(Saha, 2020).

To meet specific waste management objectives and goals, environmentally sound tannery solid
waste management, however, necessitates the selection and deployment of precise methodologies,
technologies, and management programs.This study aims to use leather trimming wastes as an
input for the production of paper. Leather trimming were subjected to multistage disintegration to
prepare powder, then treated with different monomers and applied to paper sheets.

1.2. Statement of the problem

Leather industry is one of the polluting industries that generates large amount of solid, liquid and
gaseous wastes to the environment. These wastes are classified into three types such solid, liquid
and gaseous wastes (Pappu et al., 2007). It is estimated that leather processing produces 200 times
more waste than total product output. Solid wastes from tanned and untanned hides and skins are
divided into many subgroups. Liquid waste (wastewater) is produced in much larger quantities
(Jiang et al., 2016). Solid wastes generated in Tannery manufacturing industries include rawhide
skin trimmings (5-7%), keratin wastes (2-5%), fleshing wastes (45-50%), buffing waste (25-35%).
Tannery solid wastes such as fleshings, trimmings, and shavings are proteinous wastes. In the

2
leather production industry, on average, out of 1000 kg of rawhide, roughly 800 kg of solid waste
are produced, and only 200 kg of the raw material is transformed into a usable product
(Yorgancioglu et al., 2020). Hence, they contain functional groups that can be complex with many
metals and organic molecules such as dyes. The lime trimming waste was used for various types
of ingredients for producing different products. Therefore, this study aims to use the lime trimming
waste for the production of paper products.

1.3. Objectives

1.3.1. General objective

The main objective of the research is to prepare paper from the lime trimming waste to reduce the
environmental impact.

1.3.2. Specific objectives

• To characterize the lime trimming tannery solid waste.

• To extract the collagen from untanned trimming tannery waste.
• To produce paper from lime trimming waste.
• To test the performance of the new produced paper

1.4. Justification

Paper is a necessity for human life, and there are many distinct types of it, as well as paper with
various uses for raw materials and technologies. Fiber is a necessary component of papermaking,
and the kind and quality of this raw material are tied to the nature and goals of the paper industry
as well as to the industrial system as a whole. The primary sources of fiber utilized in the paper
industry today are secondary stock, non-wood fibers (such as bamboo, wheat straw, and reed), and
lumber fiber. Because fiber quality is limited, creating paper has a relatively low quality, harming
natural resources. Chemical fiber is another raw material used in the paper industry, but due to its
high cost, it can only be used to produce high-grade synthetic fiber paper with a certain set of
properties. Although this method has produced preferable performance paper, the use of
collagenous fibers has not been refined and can't be used to play up the true physical characteristics
of collagenous fibers, which lowers the product's class and usability. Recently, someone has
developed collagenous fibers and introduced them into the string. One of the major wastes

3
produced by the leather tanning process is tannery shaving waste (CSW), lime trimming wastes
which if improperly used results in economic and environmental losses. This research work
prepares paper from the waste product of leather processing waste like lime trimming waste.

1.5. Benefits and beneficiary of the study

1.5.1. The benefits of the study

• To reduce the environmental impact due to tannery solid wastes of lime trimming waste
• To increase the input value of paper manufacturing company.

1.5.2. Beneficiary from the study

• The country
• Tannery
• Paper manufacturing company
• Researchers

1.6. Scope of the study

• This study will focus on preparing paper from lime trimming waste in wash tannery PL c
Addis Ababa.

1.7. Facility available

• Leather industry development institute (LIDI)

• Kombolicha institute of technology (leather construction lab)
• Paper manufacturing company

1.8. Implications

After the completion of this thesis work, the following outcomes are expected:

4
• Characterize and extract lime trimming tannery solid waste for an input for paper
manufacturing for best strength and quality.
• To change the tannery solid trimming solid waste to value added products.
• To reduce the environmental impact from tannery waste products.

5
CHAPTER TWO
2. LITERATURE REVIEW

2.1. Leather industry

The processing of leather involves four main stages: beamhouse, tanning, post-tanning and
finishing. The first phase of the hide processing is called beamhouse operations and involves
multiple mechanical, chemical and biological unit operations. Its objective is to remove dirt, hair,
epidermis, noncollagenous proteins and grease from raw skin, and open up the collagen fibers to
favor the subsequent tanning process (Wang et al., 2016). The process is performed in a drum by
mixing the raw hides with an alkaline solution containing lime and reducing agents, usually sulfide
salts, the hair being chemically removed from the surface of the hide (Şengil et al., 2009).

The beamhouse operations are the most water consuming and the effluents generated present very
high organic load (Mendoza-Roca et al., 2010). The leather industry is a very old branch of
manufacturing that creates a wide range of products, including leather bags, leather clothing, and
leather footwear. The waste products of the food business, notably from the processing of meat,
are the source of the raw materials utilized in the leather industry (Sivaram and Barik, 2019).

The second step in leather processing is the tanning process. Tanning is done to the leather by
using two various methods called vegetable tanning and chrome tanning (IULTCS, 2013). Chrome
tanning by using chromium sulfate chemical which is very common. Nearly 80% of all leather
produced is tanned using chromium salts (Nashy et al, 2011). Vegetable tanning is a process in
which used as natural tannin materials, present in liquid or powder form which is obtained from
different parts of plants like woods, barks, fruits, fruit pods and leaves (Covington, 2009).
In the post tanning stage, the wet blue hide and skin are converted to crust leather. In this stage,
structural differences within wet blue leathers are compensated to get a uniform structure. It
follows the following chemical and mechanical operations.

Finishing process is the finishing stage and mechanical modifications on the appearance of the
leather. The objective of finishing is to improve the appearance of leather and to give the
performance properties expected of finished concerning color, gloss, handle, flex, adhesion, rub

6
fastness as well as other characteristics as required as the final use including extensibility, light
and perspiration fastness, water vapor permeability and resistance

2.2. Leather industry waste

In leather processing, three different waste types are generated during tanning processes such as
solid, liquid and gaseous. Among 100% of rawhide, only 20-25% is converted into finished
leather about 75-80% of the rawhide converted into solid waste (Kanagarajetal,2006). The leather
processing business generates a lot of solid organic wastes, including sludge from wastewater
treatment, un-tanned (trimmings, fleshings, splits), and tanned (trimmings, splits, and shavings)
trash from raw hides and skins (Moktadir and Rahman, 2022).

Figure 1 Leather industry waste

2.2.1 Solid waste

These solid wastes are divided as untanned solid waste (before tanning process) and chromium-
containing solid waste (after tanning process) according to the tannery process. The untanned solid
wastes include trimmings, fleshing and pelt splitting. Wastes from tanned leather which includes

7
chromium sulfate chemicals are chrome shaving solid waste, wet blue trimming, buffing dust, crust
trimming and finished trimming.

A certain quantity of solid waste is produced due to the inherent characteristics of the procedures
employed in leather processing as well as the characteristics of the chemicals used. The
environment near tanneries is at risk due to these wastes (Mwinyihija, 2010). There will always be
solid waste from the leather industry. Solid waste products produced during the manufacture of
leather can be divided into the following categories:

i. Skin/hide waste from untanned animals (e.g., trimmings and fleshing wastes).
ii. Leather tanning waste (e.g., shaving waste and buffing dust).
iii. Leather dye and finishing waste (for example, trimmings).

Figure 2. Type of tannery wastes

8
When these solid wastes and byproducts are not properly handled and disposed of, they can harm
the soil and groundwater and emit noxious gases into the atmosphere through incineration or direct
landfilling, which is an unsustainable method. In the leather production industry, on average, out
of 1000 kg of rawhide, roughly 800 kg of solid waste are produced, and only 200 kg of the raw
material is transformed into a usable product (Yorgancioglu et al., 2020). Around 600,000 tons of
solid waste are produced annually by the leather industry worldwide.

Table 1 Solid waste generated in leather tannery (Yorgancioglu et al., 2020)

Solid wastes generated from processing of raw hides/skin (1000 kg) Quantity (kg)
Conservation salts 80
Hair 100
Raw trimmings 40
Lime sludges 60
Fleshings 120
Wet-blue trimmings 30
Chrome splittings 65
Chrome shavings 95
Buffing dusts 65
Crust trimmings 35
Dry sludge from common effluent treatment plants (CETPs) 125

2.3. Paper manufacturing

The pulp and paper process is important to reduce waste. Pulp is a by-product of papermaking,
and our process produces high-quality results without being detrimental to the environment. In
order to create a fiber suspension, recycled paper is combined with processed water and churned
in a massive stainless-steel vessel known as a pulper (Gavrilescu, 2008). In order to ensure that we
only generate high-quality paper that can be utilized to create high-performance packaging,
impurities are eliminated using a number of screens (Ince et al., 2011).

9
Water is taken out of the fiber solution by the paper machines. Approximately 1% fiber and 99%
water make up the solution at the beginning of the papermaking process. We can produce thin,
homogeneous paper by diluting the paper fibers in this manner. The headbox, which disperses a
consistent jet of watery stock, is located at the wet end of the paper machine (Weise et al., 1996).
The liquid splashes onto the forming material or wire. Foils (short for hydrofoils) beneath the wire
drain water and enhance fiber uniformity, ensuring that the fibers weave tightly together in a mat.
The paper sheet, often referred to as the paper web, is formed by a soft mat of pulp left behind
after the water is vacuumed out of suction boxes by the wire. The cable has now traveled 30 to 40
meters. The water content drops to between 75 and 80 percent in a matter of seconds, and the wet
sheen of the web is gone.

The paper web is next run through a succession of nip rollers, which squeeze the water out of the
pulp mat, to complete the water removal process (Hubbe and Heitmann, 2007). The fibers are also
compressed under this pressure, causing them to entangle and form a thick, smooth sheet. The
water content has dropped to about 45 and 55 percent at this point. The paper web now passes
through an enclosed area that houses many drying cylinders that are heated by steam. To make
sure the paper is now 80 to 85 percent dry, they are warmed up to 130oC using steam heat (Ghosh,
2011).

The paper is now coated with a wet sizing solution to add a thin layer of starch to the surface. The
rigidity and bonding of the paper's fibers are both aided by starch. The paper goes through another
series of heated drying cylinders after the sizing is done (Hubbe, 2006). The paper web can move
400 meters via the dry end in total. The paper is passed through a set of smooth, hard or soft, rollers
that press the paper, embossing a smooth face on the paper surface to give the containerboard a
smooth and glossy surface to optimize it for printing.

Maintaining incredibly precise control over the variables in the production process is necessary to
produce paper of the highest quality. An automated measuring device is now used to check the
paper sheet for flaws. The paper leaves the paper machine after traveling 500 meters and is
automatically wound onto a giant reel, which can weigh 60 tonnes and extend over seven meters
in length. The customer's requested paper is unwound, sliced into smaller rolls using a winder

10
nearby, and then labeled for transportation. The jumbo reel is raised by a crane to the winder
(Schirmer et al., 2014).

2.3.1 Raw material for paper production

Pulp is a primary raw material used in the production of paper. To create the paper pulp, a variety
of fibers, including cellulose and cotton, are used (Abd El-Sayed et al., 2020). Wood pulp is
currently the most widely used material for making all types of high-quality paper. It has a sizable
amount of cellulose fiber, which has the consistency of thread and serves as the foundation for the
finished product. To improve the pulp's brightness, stability, water or liquid resistance, and
capacity to remove impurities, it is blended with various chemicals and papermaking agents (Melin
and Nannfeldt, 1934).

2.4. Research gaps analysis

Large amounts of water and various chemicals are needed throughout the tanning process, and
various solid, gaseous, and liquid pollutants are produced that have a negative impact on the
environment, making the leather industry one of the most polluting businesses (Chowdhury et al.,
2017). Because different chemicals are applied to the raw hides in various quantities, these wastes
have unique properties. Salts, raw trimmings, hair wastes, fleshings, splitting wastes, chrome
shavings, buffing dusts, crust trimmings, and completed trimmings are the principal solid wastes
produced in tanneries.

11
CHAPTER THREE
3. MATERIALS AND METHODS

3.1. Chemicals and Equipment

Table 2. Chemicals for paper production

S.No Chemicals Purpose
1. Chlorine Pulp bleaching
2. Calcium magnesium carbonate Filler and coating
3. Hydrogen peroxide In pulp bleaching
4. Sodium abietate Sizing
5. Abietic acid Sizing
6. Sodium tripolyphosphate Dispersant
7. Titanium dioxide Filler to increase the opacity and brightness of paper.
Used in coating.
8. Lime trimming

3.2. Methods

3.2.1 General working procedures of the research

Figure 3. General working procedures of the research

12
3.2.2. Phase 1. Extraction of pulp fiber from lime trimming waste

Figure 4. Extraction of pulp fiber from lime trimming waste

3.2.3. Phase 2: Paper preparation from pulp fiber

Figure 5 Paper preparation procedure

3.3. Data collection methods

In this thesis work the data collection methods will be both primary and secondary data collection
techniques.
Primary data collection Secondary data collection
✓ Observation: ✓ Books:
✓ Interview: ✓ Internet
✓ Questionnaires: ✓ Journals

13
3.4. Data analysis methods

To analyze the data, an experiment design tool, Box-Behnken, will be used. Box-Behnken designs
are used to generate higher-order response surfaces using fewer required runs than a normal
factorial technique.

3.5. Finished paper test evaluation

Paper comes in an enormous variety of shapes, sizes, qualities, grades, colours and finishes.
Some of the typical characteristics used to determine paper quality are given here. The types
of tests that will be carried out on a batch of new paper depend upon the use for the paper.

✓ Weight in grams per square meter (referred to as gsm or grammage)

✓ Brightness / shade
✓ Porosity
✓ Thickness or calliper (measured in microns)
✓ Smoothness / gloss
✓ Density or bulk (a function of the previous two qualities)
✓ Oil-resistance
✓ Moisture absorption
✓ Tensile strength
✓ Moisture content
✓ Burst
✓ Folding
✓ Optical properties (adjustable using mineral fillers)

14
 CHAPTER FOUR
4. Time schedule and financial plan

4.1. Time schedule

Table 3 Time schedule

2022/23 2023/24
Activities Sept Oct Nov Dec Jan Feb Mar Apr May Jun Sep Oct Nov Dec Jan Feb
1 Literature survey
2 Material study
3 Progress writing
4 Data collection
5 Trimming characterization
6 Pulp preparation
8 Paper preparation
9 Physical testing of paper
10 Data analysis
13 Documentation
14 Final presentation

15
4.2. Financial plan

Table 4 Financial plans

LABORATORY AND CONSUMABLE CHEMICALS
Item Quantity Total amount in birr
Consumable chemicals 85 liters 95,000
Supportive labratory chemicals 45 liters 45,000
Total 140,000
PERSONAL COST
Item Quantity Total amount in birr
Periderm of the researcher 3*110*206 67,980
Data collectors 3*30*700 63,000
Pilot study 8000
Total 138,980
TRANSPORT COST
Item Quantity Total amount in birr
From Kombolcha to AA 15 round trip *3*500 22,500
Total 22,500
TESTING COST
Item Quantity Total amount in birr
Tensile strength 3samples 10,000
Tear strength 3samples 10,000
Dry rub fastness 3samples 10,000
Wet rub fastness 3samples 10,000
Weight 3samples 10,000
Brightness / shade 3samples 10,000
Porosity 3samples 10,000

Thickness 3samples 10,000

Oil-resistance 3samples 10,000

16
Moisture absorption 3samples 10,000

Moisture content 3samples 10,000

Optical properties 3samples 10,000

Total 120,000

SUMMERY
S.No Cartagory Amount in birr
1 Laboratory and consumable chemicals 140,000
2 Personal cost 138,980
3 Transportation cost 22,500
4 Testing cost 120,000
Total cost 421,480 birrs
Contingency cost (10%) 42148birrs

Total Growth cost 463,628 Birr

17
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