In-plant Process Research Articles

Water safety planning application for aesthetic quality of drinking water

ABSTRACT The World Health Organization considers water quality aesthetic parameters affecting taste, odor, and appearance, as factors to be monitored to determine the overall safety of water. Water safety plans (WSPs) can be used by utilities to proactively identify aesthetic hazards, rank them by likelihood of occurrence and consequence to the utility, generate risk scores, and provide direction on how to monitor, mitigate, and verify that controls are in place. The City of Wichita Falls Public Water System (CWF PWS) used the water safety planning approach to outline how aesthetics may negatively affect the system from source water, in-plant processes, and into the distribution system. By proactively identifying these hazards and outlining what to do using a WSP, the utility has put measures in place to ensure that aesthetically acceptable water is delivered to their customers. This article outlines the water safety planning process for water quality aesthetics and how the CWF PWS developed and implemented its WSP.

Training on the Use of Processed Herbal Plants as an Effort to Prevent Degenerative Diseases to the Community

This community service aims to increase public knowledge in health and health efforts through promotive and preventive activities by conducting counselling and training in the use of medicinal plants and how to process herbal plants properly and correctly so that people in Ndokum Siroga village, Karo Regency understand the importance of health and a healthy paradigm. by using herbal plants. This community service activity is to increase public awareness of health by introducing a healthy paradigm. The implementation method used is lectures and training where lectures are conducted to increase public knowledge about the health paradigm and the importance of health as well as the introduction of herbal plants to make family medicinal plants while the training is carried out by providing facilities and infrastructure for community service activities to increase community knowledge and skills, including delivery papers on various types of herbal plants used, things to consider in-plant processing, and their properties, as well as the practice of processing plants into drinks that are easy to consume. The conclusion of this activity is very helpful and provides good benefits to the community because this activity can have a direct impact on the community. The analysis technique and activity results are seen from the knowledge of the community before and after the training and counselling by asking questions in an objective form that can describe the different levels of understanding of the participants.

Evaluation of Enterococcus faecium NRRL B-2354 as a surrogate for Salmonella in ground black pepper at different water activities

Thermal inactivation kinetics of Salmonella in low moisture foods are necessary for developing proper thermal processing parameters for pasteurization. The effect of water activity on thermal inactivation kinetics of Salmonella and Enterococcus faecium NRRL B-2354 in ground black pepper has not been studied previously. Identification of a suitable surrogate assists in conducting in-plant process validations. Ground black pepper was inoculated with a 5-serotype Salmonella cocktail or E. faecium NRRL B-2354, equilibrated to water activities of 0.25, 0.45 or 0.65 in a humidity-controlled chamber, and isothermally treated at different temperatures. The survivor data were used for fitting the log-linear models to obtain the D and z-values of Salmonella and E. faecium in ground black pepper. Modified Bigelow models were developed to evaluate the effects of temperature and water activity on the thermal inactivation kinetics of Salmonella and E. faecium. Water activity and temperature showed significant negative effects on the thermal resistance of Salmonella and E. faecium in ground black pepper. For example, significantly higher D values of Salmonella were observed at water activity of 0.45 (D70°C = 20.5 min and D75°C = 7.8 min) compared to water activity of 0.65 (D70°C = 3.9 min and D75°C = 2.0 min). D-values of E. faecium were significantly higher than those of Salmonella at all three water activities, indicating that E. faecium is a suitable surrogate for Salmonella in thermal processing validation.

Identification and Characterization of the Expansin Genes in Triticum urartu in Response to Various Phytohormones

Expansins are ancient proteins involved in cell wall loosening during diverse biological processes in plants. They may participate inplant developmental processes and in responses to multiple external stresses. Triticum urartu is a diploid wheat, which is the A genome donor in hexaploid wheat (AABBDD). Wheat is an important agricultural crop. In this study, a total of 39 expansin (EXP) genes in T. urartu were identified and categorised into three subfamilies according to their phylogenetic relationship, consisting of 19 EXPA genes, 18 EXPB genes and 2 EXLA genes, but no EXLB genes. The structures of T. urartu EXP (TuEXP) genes were conserved. Expression analysis and transcript profiling revealed differential expression of TuEXPs in different tissues and developmental stages. Expression patterns of TuEXPs genes were also investigated in different tissues under different phytohormone treatments at the three leafstage. The expression of most of the analyzed genes were either up-or down-regulated, which could help research on expansin-related mechanisms.

A life cycle assessment study of pre-stressed concrete poles in Thailand

In recent years, global societies are increasingly concerning about environmental quality and seeking ways to mitigate environmental impacts. As such, the complete environmental profile of products is required to make the products more environmentally friendly. This study undertook a cradle-to-grave life cycle assessment (LCA) of pre-stressed concrete pole production to identify the environmental impacts from these production processes. The methodology used in this case study of a concrete pole manufacturer in Thailand was based on the environmental aspects and the impacts of processes, guided by ISO 14040:2006 and ISO 14044:2006 frameworks, before comparing the results with those for other types of utility poles in other studies. The results showed that the most significant impact of the pre-stressed concrete pole in this case study, when comparing life cycle stages, originated from transportation. After transportation, raw materials, particularly cement and steel, played important roles in contributing the most to environmental impacts. Other phases, such as installation, in-plant processing, and disposal, showed a rather limited impact in the overall results. The current study is the primary stage of a life cycle assessment (LCA) study on utility poles in Thailand. It could be beneficial in supplementing information on the environmental impacts of utility poles.

Contamination of salmon fillets and processing plants with spoilage bacteria

The processing environment of salmon processing plants represents a potential major source of bacteria causing spoilage of fresh salmon. In this study, we have identified major contamination routes of important spoilage associated species within the genera Pseudomonas, Shewanella and Photobacterium in pre-rigor processing of salmon. Bacterial counts and culture-independent 16S rRNA gene analysis on salmon fillet from seven processing plants showed higher levels of Pseudomonas spp. and Shewanella spp. in industrially processed fillets compared to salmon processed under strict hygienic conditions. Higher levels of Pseudomonas spp. and Shewanella spp. were found on fillets produced early on the production day compared to later processed fillets. The levels of Photobacterium spp. were not dependent on the processing method or time of processing. In follow-up studies of two plants, bacterial isolates (n=2101) from the in-plant processing environments (sanitized equipment/machines and seawater) and from salmon collected at different sites in the production were identified by partial 16S rRNA gene sequencing. Pseudomonas spp. dominated in equipment/machines after sanitation with 72 and 91% of samples from the two plants being Pseudomonas-positive. The phylogenetic analyses, based on partial 16S rRNA gene sequencing, showed 48 unique sequence profiles of Pseudomonas of which two were dominant. Only six profiles were found on both machines and in fillets in both plants. Shewanella spp. were found on machines after sanitation in the slaughter department while Photobacterium spp. were not detected after sanitation in any parts of the plants. Shewanella spp. and Photobacterium spp. were found on salmon in the slaughter departments. Shewanella was frequently present in seawater tanks used for bleeding/short term storage.In conclusion, this study provides new knowledge on the processing environment as a source of contamination of salmon fillets with Pseudomonas spp. and Shewanella spp., while Photobacterium spp. most likely originate from the live fish and seawater. The study show that strict hygiene during processing is a prerequisite for optimal shelf life of salmon fillets and that about 90% reductions in the initial levels of bacteria on salmon fillets can be obtained using optimal hygienic conditions.

Validation of Baking To Control Salmonella Serovars in Hamburger Bun Manufacturing, and Evaluation of Enterococcus faecium ATCC 8459 and Saccharomyces cerevisiae as Nonpathogenic Surrogate Indicators

This study was conducted to validate a simulated commercial baking process for hamburger buns to destroy Salmonella serovars and to determine the appropriateness of using nonpathogenic surrogates (Enterococcus faecium ATCC 8459 or Saccharomyces cerevisiae) for in-plant process validation studies. Wheat flour was inoculated (∼6 log CFU/g) with three Salmonella serovars (Typhimurium, Newport, or Senftenberg 775W) or with E. faecium. Dough was formed, proofed, and baked to mimic commercial manufacturing conditions. Buns were baked for up to 13 min in a conventional oven (218.3°C), with internal crumb temperature increasing to ∼100°C during the first 8 min of baking and remaining at this temperature until removal from the oven. Salmonella and E. faecium populations were undetectable by enrichment (>6-log CFU/g reductions) after 9.0 and 11.5 min of baking, respectively, and ≥5-log-cycle reductions were achieved by 6.0 and 7.75 min, respectively. D-values of Salmonella (three-serovar cocktail) and E. faecium 8459 in dough were 28.64 and 133.33, 7.61 and 55.67, and 3.14 and 14.72 min at 55, 58, and 61°C, respectively, whereas D-values of S. cerevisiae were 18.73, 5.67, and 1.03 min at 52, 55, and 58°C, respectivly. The z-values of Salmonella, E. faecium, and S. cerevisiae were 6.58, 6.25, and 4.74°C, respectively. A high level of thermal lethality was observed for baking of typical hamburger bun dough, resulting in rapid elimination of high levels of the three-strain Salmonella cocktail; however, the lethality and microbial destruction kinetics should not be extrapolated to other bakery products without further research. E. faecium demonstrated greater thermal resistance compared with Salmonella during bun baking and could serve as a conservative surrogate to validate thermal process lethality in commercial bun baking operations. Low thermal tolerance of S. cerevisiae relative to Salmonella serovars limits its usefulness as a surrogate for process validations.

Progressive measurement and monitoring for multi-resolution data in surface manufacturing considering spatial and cross correlations

Controlling variations in part surface shapes is critical to high-precision manufacturing. To estimate the surface variations, a manufacturing plant usually employs a number of multi-resolution metrology systems to measure surface flatness and roughness with limited information about surface shape. Conventional research establishes surface models by considering spatial correlation; however, the prediction accuracy is restricted by the measurement range, speed, and resolution of metrology systems. In addition, existing monitoring approaches do not locate abnormal variations and lead to high rates of false alarms or misdetections. This article proposes a new methodology for efficiently measuring and monitoring surface variations by fusing in-plant multi-resolution measurements and process information. The fusion is achieved by considering cross-correlations among the measured data and manufacturing process variables along with spatial correlations. Such cross-correlations are induced by cutting force dynamics and can be used to reduce the amount of measurements or improve prediction precision. Under a Bayesian framework, the prediction model is combined with measurements on incoming parts to progressively make inferences on surface shapes. Based on the inference, a new monitoring scheme is proposed for jointly detecting and locating defective areas without significantly increasing false alarms. A case study demonstrates the effectiveness of the method.

Development of micrologistics system of delivery of finished products of metallurgical enterprises by rail transport

Logistics flows of metallurgical enterprises have certain characteristics, conditioned by their capacity and dependence on complex technological processes. Enterprises have reliable levers of influence mostly on in-plant transport processes, therefore, the studies to improve optimization methods of transport-storehouse processes in this element of logistics chain were performed. Micrologistics systems of interaction of flow processes for basic general options of deliveries were developed, the structure of which is as follows: the flow of cargo, rolling stock, information, documents and payments is shown in the time field. Operations that are performed with the corresponding flows are marked on the ordinate axis. The proposed system is a tool to identify “bottlenecks” in the field of graph of explicitly presented processes and optimize the supply chain as a whole with minimum total costs. In fact, the research results are improved methods to develop transportation flow charts. It was proposed to optimize the system of delivery of finished products of metallurgical enterprise by in-plant transport based on logistics principles. In the improved system, the overall cargo delivery term is reduced mostly by eliminating some operations with the rolling stock. Some cargo operations and execution of documents are no longer needed. A methodology for evaluating the effectiveness of change of transport-technological process of delivery of finished products was proposed.

Study on Base Management Pattern of Food Producing Enterprise

When the food producing enterprises often comply with food safety regulations and industry management system passively, we need to consider can they transform their production and business pattern in order to avoid the food safety incidents completely? The answer is yes. The food producing enterprises can develop to the two directions of material planting and products in circulation through base management pattern substituting for the original operation pattern of in-plant processing and outside sales. The food producing enterprises should establish coordination and safe supervision mechanisms in order to achieve the management objectives of unified production, controllable risks and scale magnitude.

Reengineering in-plant logistics: a case study of Cement Manufacturing Plant in India

A firm that manufactures and delivers a tangible product, logistics is both a fundamental business activity and the underlying phenomenon that drives most other business processes. It is difficult to imagine BPR without logistics. In this paper, a case study on reengineering the in-plant logistics process in a Cement Manufacturing Plant (CMP) is presented. The finding of the study shows that BPR leads to improvement in the overall in-plant logistics process. It may be noted that every company will have their own way of implementing BPR based on their unique situations however the basic framework will remain the same.

Evaluation of Processes to Reduce Activated Sludge Solids Generation and Disposal

This project will deal with a number of aspects of WAS-only-reduction technologies for both industrial and municipal wastewater treatment applications. The objectives of this project include the following: 1. Developing an evaluation methodology that can be used to independently assess the effectiveness of WAS-reduction technologies 2. Demonstrating the previously listed methodology with at least one WAS-reduction technology This study includes not only the primary goals of establishing the degree of WAS reduction and corresponding capital and operation and maintenance (O&M) costs, but also such details as impacts on dewaterability (e.g., changes in polymer requirements, and maximum solids content achievable), changes in volatile solids reduction and corresponding biogas production in anaerobic digestion, possible odor issues in terms of in-plant processing requirements or ultimate product quality for disposal that result from these processes, and the change in characteristics of the recycle streams back to the main process (such as increased nutrient return, increased total suspended solids [TSS] return, phosphorus removal, etc.). In addition to the more technical parameters, the adopted approach also considers evaluations of operability, reliability, and maintainability on each of the leading processes. Some of these effects were determined by laboratory testing and plant data evaluation. Others were investigated through comprehensive modeling using standard industry models such as ASM 2d for liquid-stream biological treatment and the ADM1 model for anaerobic digestion. A key objective of this work is an impartial validation of these technologies and the development of a methodology for assessment of additional technologies that currently do not exist, but could be developed in the future. This requires not only real world operating data, but also a degree of understanding of the fundamental mechanism behind the process. As such, a critical part of this project involves the discussion of the potential underlying mechanisms for each of the validated technologies. This title belongs to WERF Research Report Series . ISBN: 9781843393948 (Print) ISBN: 9781780403489 (eBook)

Characterizing the Quality of Effluent and Other Contributory Sources During Peak Wet Weather Events

This study evaluates the impacts of blending practices at municipal wastewater treatment plants on effluent and receiving water quality, and estimates public health risks associated with recreation in surface waters receiving blended flows. Field samples were collected at four municipal wastewater treatment plants for in-plant processes and receiving waters during wet weather blending, wet weather non-blending, and dry weather events. Laboratory analyses for Giardia, Cryptosporidium , viruses (adenovirus, enteric viruses, rotavirus, norovirus), pathogen indicator organisms (fecal coliform E. coli , enterococcus, and male specific coliphage), and other water quality parameters were performed on these samples. Field sample results for the East Bay Municipal Utility District's (EBMUD) Main Wastewater Treatment Plant were used to develop a hydrodynamic and water quality computer models to predict receiving water conditions and a quantitative microbial risk assessment (MRA) to evaluate increased risks of gastrointestinal and respiratory infections for people recreating in waters receiving blended flows. EBMUD field sampling results indicated that Giardia and adenovirus concentrations in plant final effluent increased during wet weather blending events in comparison to non-blending events, and so receiving water modeling was conducted for these organisms. T-test results indicated that the differences between blending and non-blending were not considered to be statistically significant for any of the pathogen and indicator organisms except Giardia cysts (enumeration). Additionally, TSS, cBOD5 and particle concentrations from final effluent grab samples also appeared higher during blending events, but no increase was observed in VOC levels during these periods, and no NPDES permit limits were exceeded. An estimate of the incremental annual number of infections associated with blending practices at EBMUD's wastewater treatment plant was developed based on two pathogens (adenovirus and Giardia spp.) and three exposure sites. Estimated individual risk per exposure event for people recreating in waters receiving blended flows were greater by about an order-of-magnitude (10x) at the EBMUD MWWTP Outfall location and less than an order-of-magnitude (10x) at three other exposure sites, than if these blended flows received full secondary biological treatment during wet weather conditions. Thus the relative increase of annualized risk appeared negligible, at less than one infection annually assuming 100 exposure events per day for 30 blending days per year. This title belongs to WERF Research Report Series . ISBN: 9781843392989 (Print) ISBN: 9781780403533 (eBook)

Prevalence and antimicrobial resistance profiles of Escherichia coil O157:H7 and Salmonella isolated from feedlot lambs.

The present study examined the incidence of Escherichia coli O:H7 and Salmonella in feedlot lambs. Fifty-six feedlot lambs from eight sheep farming operations were grouped in a single drylot pen, fed, and managed as is typical in the southwestern United States. Fecal samples were collected on days 0, 46, 87, and 122 of the feeding period via rectal palpation. Wool samples (ventral midline) were collected one time only at the feedlot, immediately prior to shipping to the processing plant, and carcass swabs were collected following slaughter. All samples were cultured for E. coli O157:H7, Salmonella, and fecal coliforms, and select isolates were examined for antimicrobial susceptibility. Overall, the percentages of fecal and wool samples positive for E. coli O157:H7 averaged 9 and 18%, respectively. One carcass swab was E. coli O157:H7 positive. Of the 155 fecal samples collected, 11 (7%) were Salmonella positive. Salmonella was detected in nearly 50% of the wool samples collected prior to slaughter, while none of the carcasses were Salmonella positive 24 h postslaughter. All isolates (E. coli O157:H7, Salmonella, and fecal coliforms) were susceptible to ceftiofur, enrofloxacin, and trimethoprim-sulfamethoxazole. One E. coli O157:H7 isolate cultured from a carcass swab was resistant to seven antibiotics, and seven wool E. coli O157:H7 isolates were multidrug resistant. Results of this research demonstrate that feedlot sheep are naturally colonized with E. coli O157:H7 and Salmonella and wool can be a source of carcass contamination; however, in-plant processing procedures and intervention strategies were largely effective in preventing carcass contamination.

Incorporation of reverse logistics model into in-plant recycling process: A case of aluminium industry

In order to maximize the efficiency of ever increasing aluminium recycling, different mutually related aspects need to be optimised. Economic efficiency of aluminium recycling is crucially dependent on the costs, arising at different stages of recycling process. Among these, transportation costs represent very important part of overall cost balance. The general model, based on the principles of reverse logistics, was developed and applied with the aim of reducing the extent of internal aluminium scrap transportation required between certain production units of an aluminium manufacturing plant. Linear optimisation model was used for calculating minimum annual transport costs and optimal way of in-plant transport for two transport models in order to determine the most efficient option. In case of in-plant aluminium recycling only collected aluminium materials are transported which means that the most important factors in such case are fixed transport costs and variable transport costs, latter depending on distance, transported quantity, energy used for transport and other operating costs. In the first transport model, the direct transport of collected aluminium scrap from each individual source to in-plant processing units was assumed. In the second transport model, one collection site was assumed where scrap is collected and then transported to in-plant processing units. The optimisation model was also applied for determining a dependence of optimal transport model on annual quantities transported internally and on the distances between sources and processing units. It was found out that the annual transported quantities and distances between sources and in-plant processing units have a significant impact on the optimal transport model. The developed optimisation model showed that environmental and economic objectives are not always in conflict. It is also shown and commented which aspects influence reverse logistics model for in-plant recycling.

Real-time Utility System Optimization

ABSTRACT At the 2002 IETC, we described the benefits of a site-wide utility system simulation model that can translate all in-plant process modifications to the resulting changes in fuel, water, and electricity at the factory fence to ensure that process Btus are accurately expressed in real dollars. Last year, we demonstrated how such a model could be upgraded to an optimizer to determine the most cost-effective way to operate specific equipment items wherever the operator is faced with choices as to which equipment items to run at any time, which fuel to use, etc. The last 12 months have seen a number of “second generation” optimizers delivered to clients in Europe, the Far East, and the Americas, operating in real time. These latest models employ sophisticated data validation and reconciliation techniques to account for incomplete or conflicting plant measurements. Web-enabled reports are generated and the results of the data reconciliation can even be fed back to the site data historian as corrected plant measurements. This approach will typically reduce day-to-day utility system operating costs by between 2 and 5 percent in addition to the long-term capital and operating cost savings already identified by using this type of model at the project planning and design stage.

Management of total dissolved solids in tanning process through improved techniques

Pickling, one of the pre-tanning operations in leather processing, carried out for conditioning skins prior to tanning contributes to about 35% total dissolved solids (TDS) in the effluents. Treatment of TDS is a technological challenge. Treatment methodologies to combat TDS such as membrane separation have disadvantages of generating large quantities of solid sludge containing concentrated salts and they also suffer from operational difficulties. In-plant process control is necessary for combating TDS issues. In this paper, two approaches viz., recycle/reuse of pickle liquor for the subsequent batches as well as resorting to pickle free alum–chrome combination tanning systems have been studied. Pickle liquor from the first batch has been successfully recycled for subsequent batches with appropriate replenishments. The use of potash alum for the pH reduction process has been successfully employed in place of the conventional process. Significant levels of TDS reduction were observed through using both approaches. The strength property and organoleptic property assessments indicate that experimental leathers were comparable with those of leathers processed by the conventional process. It is believed that pickle liquor recycling and pickle free alum chrome combination tanning systems could be gainfully employed to overcome the environmental problems of TDS and chromium problems in the effluent and at the same time effectively obtain economic benefits.

Enhanced biological treatment of bleached kraft mill effluents — II. Reduction of mixed function oxygenase (MFO) induction in fish

Biological treatment studies with bleached kraft mill effluents (BKME) assessed the removal of hepatic MFO induction potency towards fish. Bench-scale activated sludge, facultative stabilization basin, and aerated stabilization basin processes were compared under conservative conditions of elevated sludge age and hydraulic retention times as well as moderate temperatures for the treatment of bleachery effluents from a modernized bleached kraft mill using oxygen delignification and 60% chlorine dioxide substitution. Optimized treatment for the removal of hard-to-degrade organics also consistently removed more than 85–90% of effluent-induced MFO activity of fish, based on laboratory bioassays. Follow-up mill-site pilot scale testing with an activated sludge treatment process in extended-aeration mode also demonstrated >90% reductions in the MFO induction potential of whole mill effluent. Characterization of various in-plant process waters sampled at the mill indicated that the softwood-line bleach plant was a major contributor (>70%) to the MFO induction potential of untreated and biologically-treated BKME.

Use of Hazard Analysis Critical Control Point and Alternative Treatments in the Production of Apple Cider

The purpose of this study was to evaluate the practices of Maryland cider producers and determine whether implementing hazard analysis critical control point (HACCP) would reduce the microbial contamination of cider. Cider producers (n = 11) were surveyed to determine existing manufacturing practices and sanitation. A training program was then conducted to inform operators of safety issues, including contamination with Escherichia coli O157:H7, and teach HACCP concepts and principles, sanitation procedures, and good manufacturing practice (GMP). Although all operators used a control strategy from one of the model HACCP plans provided, only one developed a written HACCP plan. None developed specific GMP, sanitation standard operating procedures, or sanitation monitoring records. Six operators changed or added production controls, including the exclusion of windfall apples, sanitizing apples chemically and by hot dip, and cider treatment with UV light or pasteurization. Facility inspections indicated improved sanitation and hazard control but identified ongoing problems. Microbiological evaluation of bottled cider before and after training, in-line apples, pomace, cider, and inoculated apples was conducted. E. coli O157:H7, Salmonella, or Staphylococcus aureus were not found in samples of in-line apple, pomace, and cider, or bottled cider. Generic E. coli was not isolated on in-coming apples but was found in 4 of 32 (13%) in-line samples and 3 of 17 (18%) bottled fresh cider samples, suggesting that E. coli was introduced during in-plant processing. To produce pathogen-free cider, operators must strictly conform to GMP and sanitation procedures in addition to HACCP controls. Controls aimed at preventing or eliminating pathogens on source apples are critical but alone may not be sufficient for product safety.

Measurement of thermal inertia by the reflective-cavity method

The measurement of thermal parameters is a useful tool for the evaluation of compositional or structural properties of materials of industrial interest. The increasing use of noncontact photothermal techniques to generate and sense thermal fields in materials makes thermal characterization an attractive approach for in-plant quality monitoring and process control. In an effort to increase the reliability of such measurements in conditions of unknown surface emissivity, an integrating-cavity technique is described for a quantitative evaluation of the thermal inertia of the inspected material. An analysis of the performance of such a technique as a function of the cavity geometry and internal reflectivity is presented. Examples of applications to the characterization of manufactured ceramic materials with different porosity contents are described.