Semi-Industrial Preparation of Versatile Panel Rolls from Micronized Hemp Stalks

In recent years, agricultural biomass-filled materials have been increasingly explored as sustainable alternatives to fossil-based polymers and for the development of biocomposites. In this study, micronized hemp stalks, a byproduct of the cannabis industry, were loaded into 10–20% of polypropylene/polyethylene bicomponent fibers in a cost-effective original airlaying process. The production process was developed to achieve high hemp content (up to 80%), while maintaining suitable structural and mechanical properties. Experimental analyses confirmed that the hemp-based biocomposite exhibited promising thermal conductivity values (0.068 ± 0.002 W/mK) and effective sound-attenuation capabilities that are comparable to commonly used insulating materials, such as stone wool. Furthermore, X-ray diffraction and field emission scanning electron microscopy measurements analyzed the insulation features of the hemp-based biocomposite prepared with its morphological and structural properties, revealing its high internal porosity and polymeric crystallinity. These results highlight the potential of hemp biocomposites as sustainable, economically viable alternatives for thermal and acoustic insulation applications.