This study investigated the potential of secondary sludge (SS) as urea–formaldehyde (UF) co-adhesive for particleboard manufacturing. Three proportions of SS from three conventional pulping processes were added in the formulation of particleboard manufacturing. A 33 factorial design was used. All panels were tested for thickness swell (TS), linear expansion (LE), internal bond strength (IB), flexural modulus of elasticity (MOE), flexural modulus of rupture (MOR) and formaldehyde emission. Results indicated that particleboards made with SS from thermomechanical pulp (TMP) and kraft pulp (Kraft) met the ANSI standards for LE, IB, MOE, and MOR (with 7 and 9 % UF). However, the TS of panels made with SS was higher than that of control panels and adding SS to the formulation affected negatively this property. Most of the properties studied in the particleboards made with SS from chemical–thermomechanical pulping (CTMP) process failed to meet the ANSI standards. The main advantage of using SS as co-adhesive is the reduction of formaldehyde emission, in the best case here, about 50 %, with CTMP sludge added, of the particleboards.

Pulp and paper sludge can be recycled in the manufacture of medium-density fiberboard (MDF) because it contains wood fibers. A comparative study was conducted to evaluate the properties of MDF made from virgin fibers mixed with different pulp and paper sludge sources. A factorial design was used in which factors were mill pulping processes, thermal–mechanical pulping (TMP), chemical–thermal–mechanical pulping (CTMP), and kraft pulping, and percentage of sludge mixed with virgin fibers (0, 25, 50, and 75%). Virgin fibers were obtained from paper birch wood, an underutilized species. Chemical composition, physical characteristics, pH, and buffer capacity of sludge were measured. MDF properties decreased mostly linearly with sludge content. Panel properties negatively correlated with the proportion of nonfibrous material such as ash and extractives. TMP and CTMP sludge sources produced panels of similar quality, and kraft sludge produced the lowest quality. It was concluded that the amount of sludge that can be incorporated into MDF without excessive decrease in panel quality depends on the pulping process. At 25% sludge content, all panels met ANSI quality requirements for MDF used for interior applications.