Fast fluidization of dry acid pretreated wheat straw and consequent continuous bioconversions for l-lactic acid production.

High and continuous production processes inevitably generate large amounts of production waste. PT RPG is facing problems, especially with the warehouse used to store production waste which holds 17 types of waste. The warehouse is very small, with an area of only 16 m², so it cannot accommodate all 17 types of waste. This causes difficulties in waste placement activities, creates an irregular layout, and increases the risk of work accidents. The purpose of this study is to redesign the waste warehouse in order to reduce the risk of work accidents using the Class-Based Storage method and the 6S approach. This research is quantitative and involves steps such as frequency calculation, cumulative frequency, ABC classification, proposed 6S design, and proposed 3D layout model. The results showed that the warehouse area was expanded from 16 m² to 40 m², which improved the layout for material movement based on the Pareto 80/20 principle used in the ABC classification. In addition, there was a 46% increase in the efficiency of waste placement time, which supported more effective waste handling and retrieval, ultimately reducing the risk of workplace accidents. Thus, the Class-Based Storage and 6S methods proved effective in addressing the layout and safety issues at PT RPG's warehouse. Keywords: CBS, Layout, Warehouse, 6S

Synthesis of Nanodiamond-TiO2 Composites with Excellent UV Shielding Performance and Development of a Continuous Mass Production Process

Frozen boneless milkfish is an innovative processed fishery product with high economic value, but product quality must be maintained to ensure food safety and competitiveness in the market. This study aims to analyze the suitability of frozen boneless milkfish quality at XYZ SMEs using the Statistical Process Control (SPC) approach. The quality parameters observed include sensory tests (color, aroma, taste, and texture), microbiological tests in the form of Total Plate Count (TLC), and measurements of the core temperature of the fish. The study used two storage methods, namely freezer and cold storage, with three storage periods (7, 14, and 21 days) and each was carried out three times. The results showed that all samples met the sensory quality standard with a value of ≥7, the core temperature of the fish was in the range of ≤–18°C, and the TLC value was still below the maximum limit of SNI, which is ≤5×10⁵ colonies/g. However, the results of the SPC analysis using the X-chart and R-chart control charts showed several points outside the control limits, indicating that the production process was not yet fully statistically stable. This indicates that although product quality generally meets standards, variations in the production process still need to be controlled to maintain quality consistency between batches. Therefore, the implementation of continuous quality control and production process improvements are essential to improve process stability and product quality of frozen boneless milkfish.

The electrooxidation of biomass platform molecules to produce highly value-added chemicals represents a promising technology for biomass utilization and carbon emission reduction. However, low production capacity and the lack of well-established engineering paradigms have constrained the practical application of this technology. Here, a green chemical process for the anion-exchange membrane (AEM) electrocatalytic 5-hydroxymethylfurfural oxidation (AEM-HMFOR) is proposed and applied to 2,5-furandicarboxylic acid (FDCA) production, with subsequent separation and purification. We demonstrate an optimized hundred-watt-scale AEM-HMFOR stack (164.8 W) for continuous FDCA production, with a high Faradaic efficiency (94.6%) and FDCA yield (96.2%) at 100% single-pass conversion efficiency (SPCE). This stack operates stably for over 100 hours with a space-time yield (STY) of 367.2 mg h-1 cm-2. A membrane separation device is employed to purify FDCA with an overall purity of 99.8%. Techno-economic analysis (TEA) and life cycle assessment (LCA) have certified the economic viability and environmental sustainability of the proposed AEM-HMFOR technology. These findings represent a significant advancement in the practical application of large-scale AEM-HMFOR systems coupled to green H2 production.

Process design for the continuous production of α- and γ-mangostin from mangosteen pericarp with integrated solvent recovery

Postage stamps represent a marginalized yet culturally significant medium in the history of visual communication in North Macedonia. This paper explores postage stamps issued in North Macedonia from independence (1991) to the present as visual artifacts that reproduce and transmit cultural identity. The analysis is based on a combined methodology that includes visual and semiotic analysis, as well as a contextual framework for interpreting symbols as “significant carriers of cultural memory” (Nora, 1989, p. 9). The research encompasses carefully selected postage stamps from different decades, which are analyzed according to their formal structure, use of color, typography, and symbolism. The study demonstrates that the design of these stamps is closely linked to processes of national identification, institutional stabilization, and cultural identity. As Stuart Hall emphasizes, “identity is not something already given, but a process of continuous production” (Hall, 1996, p. 4), and postage stamps function as micro-archives of this process. The aim of the paper is to show that although these visual objects function administratively, their visual structure and aesthetics contain profound cultural implications, making them a valuable subject for cultural-semiotic analysis.

Fat-filled powder has the potential to substitute milk in meeting the nutritional needs of the community, but its product quality remains unstable during continuous production processes. A key challenge in fat-filled powder (FFP) production is the difficulty in quality monitoring, which is influenced by various uncertainty factors that affect product quality. Machine learning can be implemented for quality monitoring system, but the imbalanced data conditions require the development of algorithms with optimal performance. This study aims to design a quality monitoring system for FFP using a machine learning model under imbalanced dataset conditions and the influence of other uncertainty factors. A Random Forest (RF) machine learning model was developed for monitoring FFP quality. In the context of imbalanced datasets, the model was optimized through various scenarios, including data splitting for training and testing, as well as the Synthetic Minority Oversampling Technique (SMOTE) and Distribution Optimally Balanced – Stratified Cross Validation (DOB-SCV) schemes. The results showed that the SMOTE model achieved the best performance in terms of accuracy, precision, and recall with scores of 99.67%, 99.79%, and 99.24%, respectively, on the testing data. Statistically, the RF model with the SMOTE data manipulation scenario also showed significant differences compared to the DOB-SCV model and the traditional data splitting approach. The quality monitoring model for FFP developed in this study can be implemented in the dairy industry, offering more stable, accurate quality monitoring predictions that align with real conditions, helping to avoid quality uncertainties during the production process. The implementation of this model in the industry has the potential to facilitate a broader, more transparent, and optimized product quality evaluation process, which can also be conducted in real time under continuous production conditions.

Resveratrol is an important natural product with a variety of biological activities. Plants and fruits are the primary dietary sources of resveratrol. To produce resveratrol more efficiently at a nutraceutical grade, a grape suspension cell culture was developed as an alternative resource for resveratrol. Subsequently, surface-adhesion-based immobilization of the grape cells was exploited to establish a continuous (repeated-batch) production process. The maximum resveratrol production by immobilized cells in the first batch culture reached 413 mg/L but dropped apparently in the second batch. A preimmobilization approach was further developed to enhance the grape cell adhesion on the carrier, which greatly improved the stability of continuous production. The immobilized cells were used continuously for 56 days throughout seven repeated batches with an average production of 163 mg/L, 2.2-fold higher than that of the suspension culture. This study demonstrated that surface adhesion of plant cells could be an effective method for the long-term continuous production of plant metabolites.

Perfusion technologies play a growing role in the implementation of continuous processes for biotherapeutics production in mammalian‐based manufacturing. However, their application to alternative production hosts is limited. Cell retention systems are of key importance for the efficiency of perfusion bioreactors. In this study, we investigate two cell retention technologies for the development of lab‐scale Komagataella phaffii continuous processes. An acoustic‐based process (AP) and a membrane‐based process (MP) were developed using an acoustic cell separator (ACS) and a vibrating membrane filtration (VMF) device, respectively. Both systems allowed for continuous cell recycle and production of scFv13R4 antibody fragment for 8 days (AP) and 9 days (MP), without loss in productivity, while maintaining high viability (greater than 90%). Higher volumetric and specific productivities were achieved during the AP process, namely 50.63 ± 1.63 mg L−1 day−1 and 1.09 ± 0.07 mg g−1 day−1, against the 32.29 ± 1.21 mg L−1 day−1 and 0.44 ± 0.02 mg g−1 day−1 afforded by the MP process. The VMF device provided 100% separation efficiency with biomass accumulating up to concentrations of 74.1 ± 0.1 g L−1 dry cell weight (DCW), whereas the acoustic device reached 55.1 ± 0.47 g L−1 DCW at 98% separation efficiency. The acoustic device showed selectivity towards larger and more complex cells in the yeast population, which might be linked to the observed higher productivities for the AP process. This study discusses the advantages and drawbacks of both cell retention technologies and provides an outlook towards their future investigation in K. phaffii perfusion processes.

The conversion of CO2 into valuable chemicals such as formic acid offers a promising approach to reducing CO2 emissions. This study presents a techno-economic assessment of two continuous catalytic processes for formic acid production via carbon dioxide (CO2) hydrogenation. The processes differ in the type of nitrogenous base used, operating under either homogeneous or heterogeneous catalytic conditions. Process simulations and techno-economic evaluations were performed in SuperPro DesignerTM for a medium-scale facility with an annual CO2 processing capacity of around 14 kMT. The homogeneous catalysis pathway demonstrated superior plant performance, producing 13.03 kMT of formic acid per year at 99.78% purity. In contrast, the heterogeneous pathway required higher capital investment and exhibited lower overall efficiency. The techno-economic analysis confirmed the economic viability of the homogeneous process, with a production cost of $1.18/kg and favorable investment indicators, whereas the heterogeneous route proved economically unattractive under the evaluated assumptions. Sensitivity analysis identified the selling price of formic acid as the most critical profitability parameter, with the homogeneous process remaining robust across varying conditions. Overall, homogeneous catalytic CO2 hydrogenation demonstrates a technically efficient and economically promising process for the chemical transformation of CO2, contributing to carbon management.

A novel liquid-phase plasma discharge process for single-step emulsification and continuous biodiesel production

Haemophilus influenzae type b (Hib) is a Gram-negative bacterium that causes severe infections in children under five, especially in developing countries. Although vaccination using capsular polysaccharide by Hib (linear polymer 5-D-ribitol-(1→1)-β-D-ribose-3-phosphate) conjugated to tetanus toxoid is effective, its production is complex and costly. This study aimed to develop a continuous production process for PRP to increase productivity, reduce batch numbers, and simplify manufacturing. Using a 1 L bioreactor, five dilution rates (0.13 to 0.32 h−1) were tested, with the best performance observed at 0.23 h−1, reaching a productivity of 167 mgL−1·h−1. Under optimized conditions, parameters such as free and immobilized PRP, glucose consumption, acetate formation, and biomass were monitored. The process yielded 874 mgL−1 of PRP after 74.4 h, with 78% in the free form and a final productivity of 165 mgL−1·h−1, approximately six times higher than batch processes and twice as high as fed-batch processes. The continuous process proved more efficient and required less infrastructure to meet production demands. However, further optimization is needed to enhance product quality and assess overall feasibility.

Abstract Background Lateral flow immunoassays (LFI) based on gold nanoparticles have emerged as a reliable tool for point-of-care applications. The conventional particles prepared using the Turkevich method are poorly defined in shape and size, making them unsuitable for advanced analysis. Previously, we had developed a method based upon seed-mediated growth for the synthesis of gold nanoparticles with a perfectly spherical shape. The nanospheres exhibit the narrowest optical absorption peak, making them ideal for multiplexing analysis. However, the nanospheres are capped by cetyltrimethylammonium chloride/bromide (CTAC/B), toxic ligands that also impede the binding of analytes. In general, the formation of nanospheres requires a dedicated balance between the atom deposition and surface diffusion rate. As such, dropwise addition of the precursor must be used, limiting the scale of production needed for commercial application. Here, we address these limitations by demonstrating a scalable and continuous method for the synthesis of citrate-capped gold nanospheres for advanced lateral flow immunoassays. Methods The synthesis comprises two steps. Firstly, we developed a scalable method for the synthesis of gold nanocubes with uniform edges length by introducing the precursor in one shot, followed by incubation at an elevated temperature to transform the shape from cubic to spherical. Secondly, we used a simple method to exchange the CTAC/B on the nanospheres with citrate species. It involves the deposition of an ultrathin shell of fresh gold on the nanospheres in the presence of citrate, which can serve as a reducing agent for the precursor and a ligand for further surface modification. Results The gold nanospheres synthesized in the first step have a monodispersed size from 10-35 nm. Significantly, our recent study demonstrates that this protocol can be extended to a flow reactor with a throughput of 5 × 10?6 moles of Au per minute, achieving a tenfold increase over the batch process based on the Turkevich method. It enables the large-scale production of gold colloids to meet the requirements for commercial application. In the second step, the surface-bound CTAC/B are replaced with citrate species, as confirmed by Fourier-transform infrared spectroscopy. During gold deposition, the CTAC/B desorbs while citrate species adsorb on the surface. Ultraviolet–visible spectroscopy further confirms that colloidal stability is retained after ligand exchange. In addition, our recent study demonstrates that this approach is also adaptable to a flow reactor for scalable operation. Conclusion We have developed methods for the continuous and scalable production of monodispersed gold nanospheres sought for use as color markers in diagnostic applications such as LFI. The surface of the nanospheres can be made with citrate to match that of the conventional gold colloids. As such, one can directly incorporate the gold nanospheres into current commercial devices to achieve new capabilities such as enhanced sensitivity and quantitative analysis. The successful transformation of the two-step synthesis methodology into a continuous flow reactor production process demonstrates the robustness of the innovation for commercial-scale industrial use. The transition from batch to continuous synthesis represents a step change in large-scale manufacturing simplicity, cost and quality.

Bisphenol A (BPA) is a versatile chemical compound that is essential for producing durable polycarbonate plastics and strong epoxy resins, which are integral to numerous everyday products. In the present study, BPA was prepared using phenol and acetone using a highly active and reusable ion-exchange resin (IER) Lewatit K1131S as the catalyst. Under optimized conditions, an acetone conversion of 84% and a BPA selectivity of 94% were achieved. The produced BPA was further purified, resulting in a 96% isolated yield with 99.5% purity. The reusability of Lewatit K1131S has been studied, and it was found that it can be reused multiple times without affecting the selectivity for BPA. The kinetics of the reaction was studied using the Langmuir–Hinshelwood model; it was found that the reaction follows pseudo-first-order kinetics, and the apparent activation energy was determined to be 12.7 kJ/mol. A continuous pilot scale process for the production of BPA using a fixed-bed reactor (packed with ion-exchange resin) has been developed. Pilot plant trials were conducted at different flow rates such as 200, 300, and 500 g/h, and a downstream processing methodology using an agitated thin film evaporator (ATFE) was employed for the BPA purification. This resulted in high throughput, producing 99.2% isolated BPA yield with 99.5% HPLC purity. Additionally, the robustness and viability of the catalyst were assessed at a flow rate of 200 g/h, producing 22.5 kg of BPA per kg of catalyst, highlighting its cost-effectiveness, stability, and resistance to deactivation, which shows its suitability for industrial-scale applications. The environmental viability of the process was further evaluated by using the E-factor and Process Mass Intensity (PMI) metrics. The estimated E-factor was 0.3118, while the corresponding PMI was 1.3935. These lower values indicate reduced waste generation, improved material efficiency, and enhanced sustainability of the process.

Nowadays, continuous manufacturing is a widely accepted production system in the pharmaceutical industry, as it provides several advantages over the conventional approach. The production system offers a more efficient, consistent, and uninterrupted process integrated with a real-time production system. This improvement results in high-quality products, increased uniformity, and minimized variation during production. Specifically, continuous manufacturing reduces production time by nearly 90%, improves product quality by 40%, and enhances production efficiency by 90%. Moreover, it minimizes energy and water consumption by 25–50% and requires 30–50% less working space. Consequently, it reduces manufacturing costs and supports an environmentally friendly and sustainable production practice. The transition from conventional to continuous production processes further enhances broader manufacturing capabilities and minimizes essential stockouts by improving the market supply chain during pandemics and public health emergencies. Currently, over 15 pharmaceutical products are manufactured through a continuous process and have obtained approval from the U.S. FDA, supported by regulatory frameworks including ICH Q13, which enhances universally harmonized practice. Nevertheless, the adoption of continuous manufacturing still faces numerous challenges, including regulatory approval hurdles, integration with conventional systems, requirements for consistent compliance, advanced production techniques, and the need for various stakeholder partnerships. Hence, the main objective of this review is to navigate the existing knowledge, opportunities, challenges, and regulatory approval barriers, and to highlight potential gaps related to the continuous manufacturing process. This comprehensive review of literature was conducted through searches in standard databases such as PubMed, Google Scholar, ScienceDirect, Medline, and Elsevier. The results indicate the need for harmonized and integrated efforts across multiple disciplines to design efficient strategies for overcoming regulatory hurdles and enabling wider implementation of the continuous manufacturing process.

Eukaryotic green microalgae hold potential as green-cell factories for the production of heterologous compounds such diterpenes. Previously, a C. reinhardtii UVM4 strain was genetically modified to express heterologous diterpene synthases (diTPSs) and the enzymes participating in the 2- C -methyl-D-erythritol 4-phosphate (MEP) pathway. In this work, bench-scale continuous production of manoyl oxide (MO) was performed to prove the technical feasibility of the production system and to estimate the MO production rates. Furthermore, the influence of the operational conditions like biomass concentration, light availability, and the extraction capacity on the MO productivity was assessed. In this work, we showed that it is possible to continuously produce/extract of manoyl oxide from a genetically engineered C. reinhardtii cultures in bench-scale photobioreactors, producing up to 6.7 mg L −1 d −1 . Next, we analyze the influence of the culture conditions on the biomass and manoyl oxide production rates. We found that increasing the light intensity enhances manoyl oxide production but, if diterpenes are not efficiently extracted from the culture, the MO production is significantly hindered, decreasing 7.5 times in relation to the maximum production rate. From our experimental results, we conclude that the extraction capacity is one of the most important factors affecting the efficiency of MO production in microalgal cultures and, if the extraction process is not efficient, increasing the light availability in the culture has a minor impact on the MO productivity. • Manoyl oxide was continuously produced using a genetically modified Chlamydomonas reinhardtii strain in bench scale photobioreactors. • A continuous in-situ extraction system was adopted to extract manoyl oxide using dodecane as solvent. • Biomass growth and manoyl oxide production and excretion are considered independent reactions. • Cultures with higher biomass concentration resulted in higher manoyl-oxide recovery but the overall productivity was not the highest in that condition. • Manoyl oxide productivity is mainly determined by the extraction capacity of the production system.

Abstract As a critical intermediate stage in the continuous casting and rolling process for bar production, the heating quality of a walking beam reheating furnace significantly affects billet shaping and the performance of the finished bars. To address issues such as uneven billet temperature distribution during heating, which leads to non-uniform deformation resistance in the rolling process, causing bending deformation, excessive thermal stress, and the initiation of microcracks and propagation of inherited casting cracks, this study uses 20CrNiMoA steel billets as the research object. The temperature field distribution inside the walking beam reheating furnace was simulated with ABAQUS finite element software. The accuracy of the simulation results was verified through ‘black box’ experiments, which demonstrated that the simulation precision meets the standards required for industrial applications. On this basis, the study systematically investigated the effects of temperature and time parameter settings in different heating zones of the furnace on billet temperature distribution and stress evolution. The results show that increasing the charging temperature improves temperature distribution and peak stress during the preheating stage, while lower furnace temperatures during the preheating phase reduce excessive thermal stress, and optimal furnace settings in heating zone I and II enhance heating efficiency and uniformity. The findings provide theoretical foundations and data support for optimizing on-site production heating process parameters and improving billet heating quality.

The electrosynthesis of glyoxylic acid has recently been investigated in beaker or batch electrochemical cells via cathodic reduction of oxalic acid or anodic oxidation of glyoxal. These reaction systems are constrained by non-continuous operation, where the reaction rate decreases as reactants are consumed and ultimately stops once the reactants are fully depleted. Additionally, mixed reactant systems such as undivided beaker cells increase the likelihood of side reactions and prevents having precise control over reaction conditions. While membrane-based H-cells can address these issues, they introduce additional cost and complexity to the system. This work presents the electrosynthesis of glyoxylic acid by simultaneous cathodic reduction of oxalic acid and anodic oxidation of glyoxal using a membraneless co-laminar flow reactor. Unlike batch systems, this inexpensive reactor can be operated continuously while controlling the reaction conditions of each separate product stream without using a physical membrane barrier. The co-laminar interface formed by the cathodic and anodic streams minimizes reactant crossover while allowing ion conduction. Maintaining this control with a stable co-laminar interface poses unique challenges. This presentation gives an overview of both the opportunities and constraints of this design and highlights the key developments necessary to achieve reasonable performance.Among the various design and material parameters that were explored in this study, this presentation focuses on the effects of channel dimensions, reactant concentrations, electrode wettability and electrocatalyst material. As confirmed by OCV measurements, reactant crossover was minimized by matching channel dimensions and flow rates during operation. The effect of reactant concentrations was studied via cyclic voltammetry (CV) and analysis of product concentrations via ¹H NMR and HPLC. Electrode wettability, a common challenge of carbon papers, was assessed via electrochemical active surface area (ESA) measurements and shown to improve considerably after electrooxidation treatment, resulting in a 50% increase in current density. For the cathodic reduction of oxalic acid, we demonstrate significantly improved selectivity and product yield by using lead electrocatalysts which reduce hydrogen evolution reaction (HER) and glycolic acid formation as the main side product. Overall, this study offers a continuous process for production of glyoxylic acid, while improving the major challenges of conventional synthetic methods by minimizing side reactions and enhancing reaction selectivity.

Every manufacturing company requires accurate cost information to support managerial decision-making, especially in determining the cost of goods manufactured. CV Sumber Karya Madiun is a micro, small, and medium enterprise (MSME) operating in the field of paving block manufacturing, characterized by a mass, continuous, and homogeneous production process. However, the company has not fully implemented a structured cost recording system. This study aims to analyze the calculation of the cost of goods manufactured using the process costing method. The research method used is descriptive quantitative, involving data collection through interviews, observations, and documentation at the company. Data analysis includes classifying costs into direct materials, direct labor, and factory overhead, then allocating these to three departments: Mixing, Molding, and Drying. The results show that the total production cost for February 2025 reached Rp743,471,375. The cost was distributed across three departments: Rp172,148,000 for the Mixing Department, Rp189,943,000 for the Molding Department, and Rp391,380,375 for the Drying Department. Each department’s cost was allocated according to its production function, and equivalent units were used in the drying department to calculate partially completed units and defective products. The implementation of process costing at CV Sumber Karya Madiun has the potential to enhance the accuracy of cost allocation, as well as support the establishment of more competitive selling prices and more effective future production cost planning.