Control Of Process Parameters Research Articles

Statistical Process Control and Capability Six-pack for Conductivity Measurement in Medicinal Chemical Industry

Statistical Process Control (SPC) is indispensable in the medicinal chemical industry for maintaining pharmaceutical product quality and consistency. Background: With complex chemical processes and stringent regulatory standards, robust quality control measures are essential. SPC enables monitoring and control of key process parameters, identification and correction of process variations, and ensuring final product compliance with specifications. This study evaluates the quality and capability of a process measuring medicinal raw material quality from an international chemical manufacturing company. Methods: Data collected from the conductivity measurement process were analyzed using Minitab software. The process specification was fixed at 30 µS·cm-1 as a maximum permissible limit, with 33 subgroups of size one. The computation of the capability six-pack and analysis generated six plots providing insights into process stability, recent behavior, and capability against specifications, distribution verification and capability indices. Minitab® version 17.1.0 software was used to perform a process capability six-pack analysis, including various charts and statistics to assess process stability and capability. Results: The results indicate that while the process is stable, it lacks capability, with variations exceeding acceptable limit. The process does not meet the maximum allowable specification value, with deviations from normal distribution and following logistic dispersion pattern. Conclusion: The study's novelty lies in its comprehensive yet concise presentation of key metrics essential for evaluating process capability and performance, providing insights for process improvement and quality control. Further investigation and improvement actions are needed to address sources of variation and enhance process capability and performance.

Experimental study of mechanical, morphological and thermal performance of bamboo-reinforced polylactic acid-based montmorillonite clay hybrid composite

Polylactic acid (PLA) is a promising, sustainable alternative to conventional petroleum-based polymers, but its mechanical and thermal properties limit its applications. This study introduces bamboo powders (BP) and montmorillonite clay particles (MMT) into the PLA matrix to prepare novel bio-based polymer hybrid composites using a unique combination of weight percentages of BP and MMT without chemical solvents through a stir casting process under optimised input parameters followed by compression moulding. Polymer hybrid composites were fabricated with different weight combinations, and their mechanical, morphological, and thermal properties were analysed. Tensile, flexural, and impact tests were performed to examine the mechanical performance, while thermogravimetric analysis and differential scanning calorimetry were used to assess thermal stability and characteristics. Microscopy observations showed a strong interaction between the bamboo, clay, and PLA matrix. The results revealed that the maximum tensile strength and modulus increased by 26.1 % and 40.8 %, respectively, with 10 wt% BP and 4 wt% clay content. Impact strength increased by 48 % with 15 wt% BP and 4 wt% clay content. Moreover, the thermal decomposition temperature, glass transition temperature (Tg), crystallisation temperature (Tc), and melting temperature (Tm) of the hybrid composites improved considerably with 10 wt% BP and 4 wt% clay content, increasing by 4 °C, 2 °C, and 8 °C, respectively. Based on the findings of this study, the controlled processing parameters were optimised to fabricate the bio-based composite with significantly improved mechanical and thermal properties. These properties make the composite suitable for various automotive and structural applications.

Toward efficient and industrially compatible fully textured perovskite silicon tandem solar cells: Controlled process parameters for reliable perovskite formation

AbstractCapitalizing on the existing silicon industry, fully textured perovskite‐silicon tandem solar cells have a great potential to penetrate the electricity market. While the use of textured silicon with large pyramid size (> 1 μm) enhances the power conversion efficiency (PCE), it also presents process complications. To achieve high performance, meticulous control of deposition parameters on textured silicon is required. This study provides a guideline for the use of the hybrid evaporation/spin‐coating route to form high‐quality perovskite absorbers. Using various characterization techniques, we highlight intrinsic differences between perovskite growth on flat versus textured substrates. Furthermore, we provide pathways to ensure a high perovskite phase purity, reveal mitigation strategies to avoid the formation of undesired dendritic perovskite structures, give guidelines to ensure photostability, and discuss the “misleading” effect of residual PbI2 on the perovskite photoluminescence response. A good understanding of the perovskite growth on textured silicon enables the fabrication of a tandem device with a PCE > 26% (without employing additives or surface treatments) and a good operational stability. The comprehensive guidelines in this study provide a better understanding of perovskite formation on textured silicon and can be transferred when upscaling the hybrid route perovskite deposition.

Imaging systems and techniques for fusion-based metal additive manufacturing: a review

This study presents an overview and a few case studies to explicate the transformative power of diverse imaging techniques for smart manufacturing, focusing largely on various in-situ and ex-situ imaging methods for monitoring fusion-based metal additive manufacturing (AM) processes such as directed energy deposition (DED), selective laser melting (SLM), electron beam melting (EBM). In-situ imaging techniques, encompassing high-speed cameras, thermal cameras, and digital cameras, are becoming increasingly affordable, complementary, and are emerging as vital for real-time monitoring, enabling continuous assessment of build quality. For example, high-speed cameras capture dynamic laser-material interaction, swiftly detecting defects, while thermal cameras identify thermal distribution of the melt pool and potential anomalies. The data gathered from in-situ imaging are then utilized to extract pertinent features that facilitate effective control of process parameters, thereby optimizing the AM processes and minimizing defects. On the other hand, ex-situ imaging techniques play a critical role in comprehensive component analysis. Scanning electron microscopy (SEM), optical microscopy, and 3D-profilometry enable detailed characterization of microstructural features, surface roughness, porosity, and dimensional accuracy. Employing a battery of Artificial Intelligence (AI) algorithms, information from diverse imaging and other multi-modal data sources can be fused, and thereby achieve a more comprehensive understanding of a manufacturing process. This integration enables informed decision-making for process optimization and quality assurance, as AI algorithms analyze the combined data to extract relevant insights and patterns. Ultimately, the power of imaging in additive manufacturing lies in its ability to deliver real-time monitoring, precise control, and comprehensive analysis, empowering manufacturers to achieve supreme levels of precision, reliability, and productivity in the production of components.

A New Index to Detect Process Deviations Using IR Spectroscopy and Chemometrics Process Tools

AbstractProcess analytical technologies (PATs) have transformed the beverage production management by providing real-time monitoring and control of critical process parameters through non-destructive measurements, such as those obtained with infrared (IR) spectroscopy and enabling process readjustment if necessary. New requirements in the analysis of beverages call for new methods, so in this article, we propose a method based on the construction of multivariate statistical process control (MSPC) charts from a new dissimilarity index (the evolving window dissimilarity index, EWDI) to monitor fermentation processes. The EWDI was applied to monitor wine alcoholic fermentation, the biochemical transformation of sugars into ethanol. Small-scale fermentations were carried out and analyzed using a portable mid-infrared spectrometer. In some of them, process deviations due to nitrogen deficiency or temperature changes were intentionally promoted to evaluate the performance of the EWDI. The MSPC charts build by using the fermentations carried out under normal operating conditions allowed identifying deviations of the fermentation in its early stages. Furthermore, the shape of the EWDI curve over time provides insights about the specific type of deviation occurring. These results show the potential of this new approach to improve the monitoring and control of key process stages in biochemical processes in the food industry, which allows maximizing quality and minimizing losses. Graphical Abstract

Microstructure Formations Resulting from Nanosecond and Picosecond Laser Irradiation of a Ti-Based Alloy under Controlled Atmospheric Conditions and Optimization of the Irradiation Process.

This paper presents a study and comparison of surface effects induced by picosecond and nanosecond laser modification of a Ti6Al4V alloy surface under different ambient conditions: air and argon- and nitrogen-rich atmospheres. Detailed surface characterization was performed for all experimental conditions. Damage threshold fluences for picosecond and nanosecond laser irradiation in all three ambient conditions were determined. The observed surface features were a resolidified pool of molten material, craters, hydrodynamic effects and parallel periodic surface structures. Laser-induced periodic surface structures are formed by multi-mode-beam nanosecond laser action and picosecond laser action. Crown-like structures at crater rims are specific features for picosecond Nd:YAG laser action in argon-rich ambient conditions. Elemental analysis of the surfaces indicated nitride compound formation only in the nitrogen-rich ambient conditions. The constituents of the formed plasma were also investigated. Exploring the impact of process control parameters on output responses has been undertaken within the context of laser modification under different environmental conditions. Parametric optimization of the nanosecond laser modification was carried out by implementing an advanced method based on Taguchi's parametric design and multivariate statistical techniques, and optimal settings are proposed for each atmosphere.

Raman spectroscopy online monitoring of biomass production, intracellular metabolites and carbon substrates during submerged fermentation of oleaginous and carotenogenic microorganisms

BackgroundMonitoring and control of both growth media and microbial biomass is extremely important for the development of economical bioprocesses. Unfortunately, process monitoring is still dependent on a limited number of standard parameters (pH, temperature, gasses etc.), while the critical process parameters, such as biomass, product and substrate concentrations, are rarely assessable in-line. Bioprocess optimization and monitoring will greatly benefit from advanced spectroscopy-based sensors that enable real-time monitoring and control. Here, Fourier transform (FT) Raman spectroscopy measurement via flow cell in a recirculatory loop, in combination with predictive data modeling, was assessed as a fast, low-cost, and highly sensitive process analytical technology (PAT) system for online monitoring of critical process parameters. To show the general applicability of the method, submerged fermentation was monitored using two different oleaginous and carotenogenic microorganisms grown on two different carbon substrates: glucose fermentation by yeast Rhodotorula toruloides and glycerol fermentation by marine thraustochytrid Schizochytrium sp. Additionally, the online FT-Raman spectroscopy approach was compared with two at-line spectroscopic methods, namely FT-Raman and FT-infrared spectroscopies in high throughput screening (HTS) setups.ResultsThe system can provide real-time concentration data on carbon substrate (glucose and glycerol) utilization, and production of biomass, carotenoid pigments, and lipids (triglycerides and free fatty acids). Robust multivariate regression models were developed and showed high level of correlation between the online FT-Raman spectral data and reference measurements, with coefficients of determination (R2) in the 0.94–0.99 and 0.89–0.99 range for all concentration parameters of Rhodotorula and Schizochytrium fermentation, respectively. The online FT-Raman spectroscopy approach was superior to the at-line methods since the obtained information was more comprehensive, timely and provided more precise concentration profiles.ConclusionsThe FT-Raman spectroscopy system with a flow measurement cell in a recirculatory loop, in combination with prediction models, can simultaneously provide real-time concentration data on carbon substrate utilization, and production of biomass, carotenoid pigments, and lipids. This data enables monitoring of dynamic behaviour of oleaginous and carotenogenic microorganisms, and thus can provide critical process parameters for process optimization and control. Overall, this study demonstrated the feasibility of using FT-Raman spectroscopy for online monitoring of fermentation processes.

The Application of Peroxide for Organic Synthesis in Continuous Flow Chemistry

AbstractPeroxides, as high-efficiency oxidants, are widely used in various areas of industry, such as chemical, pharmaceutical, environmental protection, etc. However, their applications in batches are limited due to their explosive and unstable nature. Continuous flow reactions have the advantages of a large area-to-surface ratio, high mixing efficiency, high mass and heat transfer performance, accurate control of process parameters, and high security. These are beneficial for the improvement of the product yield and the reduction of the reaction time and risk. Thus, in the reaction involving peroxide, continuous flow technology can effectively improve the operational safety and enhance the reaction efficiency of peroxides. This review summarized the applications of peroxides in various organic syntheses in continuous-flow chemistry. These examples illustrated the promising prospects of peroxides in green organic synthesis.

The influence of the laser cutting process parameters on the quality of the cut edge

The article describes the influence of the parameters of laser cutting on the cut edge quality of 10 mm S355J2 structural steel. The cutting process was carried out with a fiber laser. The basic evaluation criteria were measurements of perpendicularity tolerance, average profile height of roughness Rz5, visual evaluation, and measurements of hardness HV10. Moreover, the factorial regression models were prepared to investigate the standardized effects of the process parameters on the cutting quality. The variable process parameters were laser beam power, cutting velocity and working gas pressure. For regression modeling, low and high levels of these factors were considered representing the effective range of each parameter. The research presented in this paper proves that there are statistical correlations between the examined factors that have a significant impact on the achieved cutting effect. By the analysis of the process control parameters, it is possible to achieve an optimal level of quality that facilitates further technological operations on a given cutting product.

Effect of re‐fed meat in beef hamburger production

AbstractBackgroundIn food production, re‐feeding material into the manufacturing process is common practice to meet ecological and economical requirements. In production of hamburgers, the products with external imperfections are re‐fed in a frozen, coarsely crushed state.ResultsIn this study, the influence of the addition of frozen, pre‐crushed hamburgers (re‐fed meat) during the manufacturing process on the structural, physico‐chemical, functional, and quality attributes of the hamburgers was assessed. The recording of process control parameters showed no changes among the samples. It was further found that most of the studied parameters remained nearly unaffected by the addition of re‐fed meat (RFM) up to 20%. Neither the specific mechanical energy input during grinding, the histologically determined amount of non‐intact cells, nor the sensory characterization of the samples differed strongly upon the addition of RFM.ConclusionThe results indicate that it is technologically feasible to re‐feed unimpaired, high‐quality material due to ecological and economical reasons and still maintain high product quality. However, to ensure product safety, microbiological and hygienic standards must be maintained and controlled during processing.

Roll-to-roll fabrication of silver/silver chloride coated yarns for dry electrodes and applications in biosignal monitoring

This work presents a continuous roll-to-roll electrochemical coating system for producing silver/silver chloride (Ag/AgCl)-coated yarns, and their application in e-textile electrodes for biosignal monitoring. Ag/AgCl is one of the most preferred electrode materials as an interface between the conductive backbone of an electrode and skin. E-textile Ag/AgCl-coated multi-filament nylon yarns offer stable, flexible, and breathable alternatives to standard rigid or flexible film-based Ag/AgCl electrodes. The developed system allows for highly controlled process parameters to achieve stable and uniform AgCl film deposition on Ag-coated nylon yarns. The electrical, electrochemical properties, and morphology of the coated yarns were characterized. Dry electrodes were fabricated and could measure electrocardiogram (ECG) signals with comparable performance to standard gel electrodes. Ag/AgCl e-textile electrodes demonstrated high stability, with low average polarization potential (1.22 mV/min) compared with Ag-coated electrodes (3.79 mV/min), low impedance (below 2 MΩ, 0.1–150 Hz), and are excellent candidates for heart rate detection and monitoring.

Continuous Stripping with Dense Carbon Dioxide.

The integration of flow chemistry into continuous manufacturing requires efficient, controllable, and continuous methods for the concentration of diluted solutions on relatively small scales. The design and application examples of a new continuous solvent removal process are presented. The continuous stripping method employing dense carbon dioxide is based on the formation of homogeneous mixtures of dilute organic solutions of the target molecules with a large excess of carbon dioxide at temperatures as low as 35 °C and pressures around 10 MPa. Subsequent pressure reduction results in the quick release of carbon dioxide and vaporization of a significant fraction of the organic solvent. The concentration of the solute in the separated liquid phase can be up to 40 times higher than in the feed. Among the many controllable process parameters, the most significant ones are the mass-flow rate ratio of carbon dioxide to the feed and the temperature of the phase separator. By careful setting of the operational parameters, the degree of concentration enhancement may be accurately controlled. The new apparatus-despite consisting of laboratory equipment and being built in a fume hood-could easily support pilot-scale synthetic flow chemistry, being a continuous, efficient alternative to thermal concentration methods.

Surface design and engineering of ZnMn2O4/RGO composites for highly stable supercapacitor devices

The manipulation of phase and morphology of metal oxides by controlled engineering is considered to be a significant approach for enhancing electrochemical characteristics. The development of composite materials that are both highly efficient and cost-effective is crucial in the context of supercapacitors. A hydrothermal route is opted to fabricate ZnMn2O4/RGO microsphere electrodes. The control of process parameters during the synthesis and subsequent annealing allows for the development of microspheres exhibiting unique topographies of the surface. The incorporation of RGO into the composites has the potential to enhance conductivity, hence improving the overall utilization of the material. The ZnMn2O4/RGO composites exhibited the specific capacitances of 628, 545, 488, 446, 380 and 364 F g−1 at current densities of 1, 2,3,5,10 and 20 A g−1, respectively. Furthermore, the results demonstrated exceptional rate capability as the material retained 58 % of its initial capacitance even under a high current density. In addition, it retained a capacitance of 95.2 % even after 10,000 cycles at 1 A g−1. Furthermore, ZnMn2O4/RGO@ASC device displayed a reasonable specific capacitance of 128.7 F g−1 at 1.5 A g−1 and retained a capacitance of 83.9 % for 5000 cycles at 5 A g−1. The ZnMn2O4/RGO@ASC device had the energy density of 40.2 W h kg−1 at a power density of 1125 W/ kg. As a result, developed supercapacitor devices are preferred for use in portable electronics and industrial applications.

A Facile Two-Step Thermal Process for Producing a Dense, Phase-Pure, Cubic Ta-Doped Lithium Lanthanum Zirconium Oxide Electrolyte for Upscaling

An inorganic solid electrolyte is the most favorable candidate for replacing flammable liquid electrolytes in lithium batteries. Lithium lanthanum zirconium oxide (LLZO) is considered a promising solid electrolyte due to its safe operating potential window (0–5 V) combined with its good electrochemical stability. In this work, 250 g batches of pre-sintered Ta-doped LLZO (Li7La3Zr1.6Ta0.4O12, Ta-LLZO) were synthesized for bulk production of a dense LLZO electrolyte. A simple two-step thermal treatment process was developed. The first thermal step at 950 °C initiates nucleation of LLZO, with carefully controlled process parameters such as heating atmosphere, temperature, and dopant concentration. In the second thermal step at 1150 °C, sintered discs were obtained as solid electrolytes, with relative densities of 96%. X-ray diffraction analysis confirmed the phase purity of the sintered Ta-LLZO disc, and refined data were used to calculate the lattice parameter (12.944 Å). Furthermore, the presence of the Ta dopant in the disc was confirmed through X-ray photoelectron spectroscopy (XPS) analysis. The ionic and electronic conductivity values of the Ta-LLZO disc were 10−4 S cm−1 and 10−10 S cm−1, respectively. These values confirm that the prepared (Ta-LLZO) discs exhibit ionic conductivity while being electronically insulating, being suitable for use as solid electrolytes with the requisite electrical properties.

Utilizing an Ultrasonic Inspection System Operating Inside an Autoclave and Machine Learning to Quantify Porosity within Composites During Cure

ABSTRACT Composite materials are increasingly being utilized in aerospace applications for their high stiffness and strength to weight ratios and fatigue resistance. However, defects in the composite may arise during cure (e.g. porosity, delamination, fiber waviness), and current technology only allows for post-cure evaluation (e.g. microscopy, ultrasonic inspection). A high-temperature ultrasonic scanning system was developed for deployment in an autoclave, which can detect porosity in composites during the cure process. This study focused on the implementation of machine learning techniques to help generate a model that can quantify porosity, in addition to detection and localization that has previously been demonstrated. Two, six-hour-long experiments were conducted on curing of 762 mm × 305 mm (30 in. ×12 in.) composite panels with a [0/45/90/-45]4s layup and varying regions of high and low pressure due to its tapered geometry in contact with a flat caul plate. The first experiment utilized a thick (12.7 mm) caul plate and the second utilized a thin (3.2 mm) caul plate. During experimentation, within the scan area (406 mm × 13 mm), data was recorded and stored for ultrasonic amplitude. Additional variables were measured or predicted including temperature, autoclave pressure, number of plies, slope of the composite panel surface with respect to the transducer, viscosity, and glass transition temperature. The pre-processed data was entered into the Regression Learner Application in MATLABⓇ,1 and a rational quadratic Gaussian process regression (GPR) was chosen for the machine learning algorithm. The model was then trained on a larger data set to make it more robust and capable of predictions using a function callout. The result was a machine learning algorithm that can reliably quantify porosity in a composite panel during cure based on measured amplitude response and generate images for intuitive visualization. This tool can be further trained with more experimentation and potentially employed for real-time porosity detection and quantification of composite components during cure in an autoclave. Practical use of this technology is the potential to dynamically control processing parameters (e.g. autoclave pressure) in real-time to reduce the level of porosity within the laminate to acceptable limits (e.g. 2% by volume).

Advanced Manufacturing, Formulation and Microencapsulation of Therapeutic Phages.

Manufacturing and formulation of stable, high purity, and high dose bacteriophage drug products (DPs) suitable for clinical usage would benefit from improved process monitoring and control of critical process parameters that affect product quality attributes. Chemistry, Manufacturing, and Controls (CMC) for both upstream (USP) and downstream processes (DSP) need mapping of critical process parameters (CPP) and linking these to critical quality attributes (CQA) to ensure quality and consistency of phage drug substance (DS) and DPs development. Single-use technologies are increasingly becoming the go-to manufacturing option with benefits both for phage bioprocess development at the engineering run research stage and for final manufacture of the phage DS. Future phage DPs under clinical development will benefit from implementation of process analytical technologies (PAT) for better process monitoring and control. These are increasingly being used to improve process robustness (to reduce batch-to-batch variability) and productivity (yielding high phage titers). Precise delivery of stable phage DPs that are suitably formulated as liquids, gels, solid-oral dosage forms, and so forth, could significantly enhance efficacy of phage therapy outcomes. Pre-clinical development of phage DPs must include at an early stage of development, considerations for their formulation including their characterization of physiochemical properties (size, charge, etc.), buffer pH and osmolality, compatibility with regulatory approved excipients, storage stability (packaging, temperature, humidity, etc.), ease of application, patient compliance, ease of manufacturability using scalable manufacturing unit operations, cost, and regulatory requirements.

Design of Double Tank Liquid Level Control System Based on Fuzzy PID

Liquid level is one of the main parameters in industrial production process control. There are many problems such as interference and delay in the dual capacity water tank. It is usually difficult to meet the strict production requirements with the conventional PID control scheme. The corresponding transfer function is firstly deduced through the material balance equation in this article. By testing, the performance of conventional PID needs to be further improved. Then build the fuzzy PID model in Matlab/simulink and carry out simulation verification. By comparing with the PID simulation effect, the results show that under fuzzy PID control, the overshoot of the system is effectively reduced and the adaptability is strong. It reflects that the control strategy has a good reference value.

Investigation of microstructure and texture as related to primary recrystallization of grain-oriented silicon steel

Grain-oriented silicon steel requires a very strong Goss {110}<001> texture and as such a comprehensive control of thermo-mechanical processing parameters is required to achieve a strict control of texture. In particular the cold rolling and decarburization annealing process parameters have a determining effect on the grain size, the grain size distribution and the crystal texture distribution. In this study, the effect of cold rolling reduction on texture distribution in cold-rolled sheet has been analyzed. Secondary recrystallization of grain-oriented silicon steel is also highly dependent on the microstructure and texture after primary recrystallization. The influence of annealing temperature and carbides on the primary recrystallization process has also been investigated by measurements of grain growth and texture following primary recrystallization. By optimizing the microstructure and the texture of primary recrystallization of grain-oriented silicon steel, it is shown that a grain-oriented silicon steel exhibiting high magnetic induction low iron loss has been developed at Shougang Steel.

Enhancing wettability of sapphire (Al2O3) substrate through laser surface texturing

Sapphire (Al2O3) has emerged as an incredibly versatile ceramic material, attracting significant interest across various fields due to its superior properties. The potential to control its wettability offers opportunities for enhancing the functionalities of sapphire-based devices. This study focuses on achieving superhydrophilic surfaces on sapphire substrates using a 355 nm nanosecond laser. The effects of the Laser Surface Texturing (LST) parameters on the morphology and wettability of the samples were examined through a Taguchi L16 experimental design. The results showed that the repetition rate and scanning speed influenced the Contact Angle (CA) and Surface Roughness (Ra) of the laser-textured sapphire. Lower repetition rates and higher scanning speeds resulted in rougher surfaces and smaller contact angles. The minimum CA of 4.5° was obtained at a repetition rate of 50 kHz and a scanning speed of 1100 mm/s. The study highlights the importance of controlling processing parameters to achieve desired wetting properties for superhydrophilic surfaces. The findings of this research provide insights into the application of LST for achieving superhydrophilic surfaces on sapphire substrates.

Enhancing Textile Wastewater Treatment Performance: Optimization and Troubleshooting (Decision Support) via GPS-X Model

Textile factory water consumption could be optimized to minimize the generation of wastewater, reduce treatment costs, and promote resource recovery. However, downstream plant operation and management is a prime concern in the textile industry, particularly bringing treated wastewater effluent to an acceptable discharge limit. The aim of the study was to optimize key process control parameters to the observed operational challenges of existing processes and suggest an operational guide to the operators and decision makers to enhance the treatment performance in GPS-X. The formulated troubleshooting and decision support strategy, and the optimization results of waste-activated sludge in the primary and secondary clarifiers, was within the range of 15 ± 5 m3/d and 83 ± 7 m3/d, respectively, with a recycle-activated sludge flow of 150 ± 10 m3/d. The sludge retention time was 5 ± 1 d and 6.7 ± 0.5 d in the secondary and primary clarifiers, respectively. The addition of a carbon source in the form of molasses had a flow of 0.5 ± 0.05 m3/d, and the variation in the influent due to wastewater characteristics and rainfall was optimized to 600 ± 50 m3/d. The optimum air flow into the aeration tank was 550 ± 5 m3/hr and saved 91.5% of energy in the optimized process. Thus, the study is indispensable for the effective and efficient operation of the plant and serves as a good guide to the plant operators and decision makers for the best course of action.