Reduction Of Production Losses Research Articles

Innovation of Energy Technologies of Food Raw Material Dehydration and Extraction

The researchings of raw material dehydration and extraction are analyzed. The energy problems of product dehydration processes are analyzed. It is shown that recent trends in the development of heat and mass transfer technology are associated with the use of electromagnetic energy generators. The aim of the work is reduction of energy consumption during liquid phase removing from solid plant raw material and reduction of product losses from oil-containing food-industry waste. Achievement of this aim lies with a hypothesis that the use of electromagnetic energy sources in the process of removing moisture from food raw material containing a solid phase will allow to form an additional flow of the liquid phase, in addition to the traditional outlet of the vapor phase. The driving force of such a flow is the effect resulting from the local dissipation of electromagnetic energy in the solid phase volume. A mathematical model of the dehydration process is presented and a set of experimental studies was carried out, which confirmed the validity of the hypothesis. The most significant result of the work is proof of the possibility to organize modes when the juice yield is 4 times higher than the steam yield and, accordingly, to reduce energy consumption for product dehydration. The scientific significance of the obtained results is that a new effect was obtained in the work, which the authors called parodynamic. The practical significance of the work consists of proposing of the technological line for processing oilcontaining waste: coffee sludge, coffee beans husk, reagents (clay and perlite).

Physics-based vibration feature for detecting eccentric workpiece/runout faults during continuous generating gear grinding processes

Continuous generating gear grinding is a well-established and widely used process in the industry for large-scale production gears. It offers an economic/efficient process for finishing gears, which shapes the micro-geometry of the gear tooth flank and improves its surface quality. The resulting quality of ground gears depends on several factors, namely the tool performance, the machine stability as well as the correct clamping/positioning of the workpiece. The grinding step is very crucial since it has a direct impact on the operating quality of gears and in particular on the running noise behaviour of the end product. The potential of online vibration-based gear grinding monitoring has been explored and demonstrated in the previous work (Gryllias et al., 2017) as a means of quality control that could lead to the overall reduction of production losses and to the prevention of sending defective parts to customers. Several features which could be used to monitor the grinding processes and to identify a specific type of defects have been proposed & experimentally validated to some extent. The types of faults include (i) high feed rate, (ii) high infeed, (iii) non-flat workpiece, and (iv) eccentric workpiece. However, a further investigation on a new test campaign revealed that none of the features developed in (Gryllias et al., 2017) was robust enough to detect eccentric workpieces during the grinding process. It is worth mentioning here that an eccentric workpiece fault is unlikely to happen, but it is analogous to a runout on the incoming workpiece quality. In this paper, a qualitative model to predict the vibration signature due to eccentric workpieces/runouts is developed and discussed. Based on the qualitative understanding, a novel feature to detect eccentric workpieces/runouts during gear grinding processes based on vibration signals has been developed. The newly developed feature has been validated on real vibration signals captured during the emulation of process malfunctions on an industrial gear grinding machine. In this study, it is shown that the novel feature seems sensitive and robust for detecting workpiece eccentricities/runout errors of about more than 60 µm. It is also shown in this study that the feature is insensitive to other types of gear grinding faults, which is important for diagnostics/root-cause analysis purposes.

Importance of process conditions in the displacement of protein concentrates from spiral-wound membrane modules

Displacement processes accompany every start-up or shut-down of spiral-wound membrane module plants used for the production of food concentrates. In this process, large amounts of product are usually discarded due to dilution with the displacing fluid. In order to reduce product losses by improved process control, the relationships between the key process conditions and the duration of the displacement of non-Newtonian products from spiral-wound membrane modules need to be known. While previous studies assess the impact of single factors on the duration of the displacement, we reveal that considering one factor at a time is not sufficient for describing the displacement duration because the factors interact. Our conclusions are based on statistical designs of experiments and response surface models. As expected, the models suggest that the flow rate, the spacer dimensions, and the concentrate viscosity affect the displacement duration. Moreover, the models reveal interactions of the mentioned factors. Surprisingly, neither the temperature nor the viscosity of the displacing fluid turned out to have a significant effect on the displacement duration. Finally, the Reynolds number was not identified as a predictor for the displacement duration. The practical relevance of the study is that displacement durations become more predictable allowing improved process control and thus an option for the reduction of product losses during displacement processes.

Plant using Vibration Analysis

Timely detection of fault and taking corrective measures reduces the downtime of any industry. It also increases the reliability and efficiency of the system. Nowadays, many industries have implemented condition monitoring (or condition based maintenance) techniques as a part of maintenance strategies. Condition based maintenance monitors the health condition of machine and diagnose the defect if any. Though there are various condition monitoring techniques, vibration analysis is one of the strongest and widely used technique for fault identification. It is used to diagnose the fault of rotating machine element. In a big power plant, condition monitoring techniques play an important role to reduce the downtime of primary system and its auxiliaries, which in turn leads to reduction in productivity loss. Therefore, it is desirable to ensure system availability.

Effect of silver nanoparticles on product loss reduction under technological stress

Silver nanoparticles, which until recently were used as an antibacterial agent, are of great interest. In our study, we tested them as an effective anti-stress agent for animals subjected to short-term stressors – transport and pre-slaughter. Intramuscular administration of silver nanoparticles at a dose of 0.01 and 0.05 mg/kg body weight for seven days before technological stress had a positive effect on the adaptive qualities of animals. In the control group, weight loss in 18-month-old bulls weighing 481.6 kg were 2.0% (P <0.05) and 1.8% (P <0.05) higher, respectively. At the same time, during transport and pre-slaughter the loss of body weight in animals of the experimental groups was 19.3% and 13.6% lower compared to the control group. The best results were obtained for bulls, which were intramuscularly injected with emulsion of silver nanoparticles at a dose of 0.01 mg/kg body weight.

PREVENTING THE ROD STRING REVERSE BY APPLYING FLEXIBLE COUPLING GROUP AND ANAEROBIC HERMETICAL MATERIALS IN BASHNEFT-PRODUCTION Ltd

Currently, the main goals in the field of oil and gas production include costreduction and reduction of production losses due to increased efficiency of operation of the mechanized well stock. At the fields of Bashneft Production Ltd, the production of oil wells is operated mainly by means of sucker-rod well pumping units, therefore, increasing the efficiency of this method of oil production is a priority task. The proposed article discusses the analysis of well stock failures due to the top of the rod string and the main causes of the cuffs, as well as measures developed and implemented to reduce the number of failures due to the top of the column string.

Economic and Social Effects of Rice Cultivation Practices Operation (Case Study: Rice Cultivator Villages in Rasht County)

Economic and Social Effects of Rice Cultivation Practices Operation (Case Study: Rice Cultivator Villages in Rasht County)

Shelf life extension as solution for environmental impact mitigation: A case study for bakery products

Over the last years, increasing attention has been paid to environmental concerns related to food production and potential solutions to this issue. Among the different strategies being considered to reduce the impact food production has on the environment, only moderate has been paid to the extension of shelf life; a longer shelf life can reduce food losses as well as the economic and environmental impacts of the distribution logistics.The aim of this study is to assess the environmental performance of whole-wheat breadsticks with extended shelf lives and to evaluate whether the shelf-life extension is an effective mitigation solution from an environmental point of view. To this purpose, the life cycle assessment (LCA) approach was applied from a “cradle-to-grave” perspective. Rosmarinic acid was used as an antioxidant to extend the shelf life.To test the robustness of the results and to investigate the influence of the choices made in the modelling phase, a sensitivity and uncertainty analysis were carried out.The achieved results highlighted how, for 10 of the 12 evaluated impact categories, the shelf-life extension is a proper mitigation solution, and its effectiveness depends on the magnitude of product loss reduction that is achieved. The shelf-life extension doesn't allow for the reduction of environmental impact in the categories of human toxicity, cancer effects and freshwater eutrophication.

Development and application of edible film of active potato starch to extend mini panettone shelf life

Physicochemical properties may determine quality attributes and consumer acceptability of mini panettones. To reduce the conservatives added in food, this study developed active edible films of potato starch, inverted sugar and sucrose to coat mini panettones. All three variables significantly affected (p < 0.05) moisture, aw, hardness and elasticity of panettones. The selected formulation (46 g/kg starch, 14 g/kg inverted sugar and 7 g/kg sucrose) was added to potassium sorbate (1 g/kg), citric acid (10 g/kg) and both additives (1 g/kg sorbate + 10 g/kg citric acid and 0.5 g/kg sorbate + 5 g/kg citric acid). From 16 to 24 days (35 °C/60% RH), panettones without coating and without additives (controls) showed growth of mold/yeast; while with both additives coating, fungal growth was observed from 40 days. When using potassium sorbate, mold/yeast was not detected until 48 days. During storage, there was reduced water activity, moisture, elasticity and cohesiveness of panettones with additives, while the reverse occurred in controls. The incorporation of food-graded antimicrobial compounds in the packaging films of potato starch coatings in concentrations lower than those normally used for mini panettones increased up to 130% their shelf life and may contribute to product loss reduction during storage.

Investigation of prospects and problems of lean technologies introduction in Russian enterprises

The use of lean technologies as the key component of the concept of lean manufacturing is discussed in the article. The main aim of the work is the analysis of the theoretical foundations, basic principles and tools of lean management and evaluation of the prospects and obstacles encountered in the implementation of lean in manufacturing plants in Russia. The main result is the formulation of recommendations on the transition of Russian enterprises from traditional management to lean management.Implementation and development of lean production technologies provides a number of advantages, such as: reduction of production losses, reduction of production costs, increasing productivity while reducing labor costs, improving product quality, increasing yield. The basic lean tools are discussed. The field of application and the place in the chain of measures to improve the processes and products of the company were defined. Key issues - constrained factors of the transition to the concept of lean manufacturing were identified. Research confirmed the importance of the sequence of steps in the lean implementation, the starting point for this is the request of the consumer market to the technical specifications and consumer products. The research results can be applied in business optimization processes through the introduction of lean technologies in manufacturing plants, retail and service sectors. The company offers to improve the competitiveness of the implement, change or improve its own production concept, based on the synergistic effect of the introduction of the integrated lean technology.

METHODS OF EXTRACTION OF POLYHYDROXYALKANOATES FROM BACTERIAL BIOMASS

Polyhydroxyalkanoates (PHAs) are biodegradable and biocompatible polyesters intracellularly accumulated by many bacteria as an energy reserve material and carbon source. These biopolymers may be extracted from cells after their production phase, and the extraction process involves various individual operations to ensure adequate removal of the biopolymer from the cells. During this process, the following aspects should be considered: reduction of product losses during different stages of the process to obtain a highly pure product, preservation of physical and thermal characteristics, and use of low toxicity chemicals to achieve sustainable production and avoid harming the environment. The impact of the costs of PHA extraction on the total cost of the production process may account for over 50% of the end-value of the product. Within this context, several methods of PHA extraction have been reported in the literature. These methods include the use of solvents, chemical digestion, enzymatic digestion, mechanical extraction with high-pressure homogenization and ultrasound, extraction using supercritical fluids, or a combination of these methods. The present review of the literature shows strategies for extraction processes of PHAs produced by bacteria involving cell destabilization and/or breakage, recovery, and purification of the biopolymer.

Software to Improve Control System in an Ethanol Distillation Process

This work has developed a predictive control solution based on specific models for the process of ethanol distillation. The advantages of such control are relative to the prediction of the consequences of the disturbances by the model, thus enabling the control action to be done in a previous manner, resulting in the minimization of the variables fluctuation controlled by the process. This results in, among other advantages, energy economy, in the improvement of the ethanol produced and in the increasing production capacity. Another desirable characteristic in this control mode is its capacity to act in non-linear systems as is the case of the distillation columns. Finally, it must be noted that with the application of an advanced control solution, as proposed in this study, it becomes viable, in a second moment, for the ethanol plants to operate in multiple operational conditions, such as: 1) maximum energy economy (scarcity of raw material, for example) and: 2) maximum production condition (for situations with excess of materials to be distilled). The models developed in this project will consist of purely empirical models. Several tests will be done in the different types of models to measure the precision and robustness. The proposed control strategy demonstrated be able to control selected control loops adequately. Steam savings and reduction of product losses were observed.

Consistency of Return to Normal Function, Productivity, and Satisfaction Following Migraine Attacks Treated With Sumatriptan/Naproxen Sodium Combination

To assess the consistency of improved functioning, productivity, and medication satisfaction in migraines treated with a single tablet of sumatriptan 85 mg/naproxen sodium 500 mg (S/NS) using an early intervention approach. Two randomized, double-blind, placebo-controlled, 4-period crossover, multi-attack, multi-center, outpatient studies of moderate to severe adult migraineurs were conducted to compare S/NS with placebo. Participants recorded outcome assessments in a diary during the 24 hours following study medication. Analyses were conducted on the intent-to-treat population who treated at least 1 attack. Statistical significance between treatment groups used analysis of variance repeated measures models and the intent-to-treat population. There were no corrections for multiplicity. Almost half (48.5%) of migraineurs treated with S/NS returned to normal functioning at 2 hours and 73.3% at 4 hours postdose, compared with 28.7% (2 hours) and 43.3% (4 hours) of placebo-treated attacks. Total productivity loss over the 24 hours postdose was significantly reduced following S/NS treatment (2.5 hours on average) compared with placebo (4.0 hours). Sumatriptan/naproxen treatment resulted in significantly higher medication satisfaction scores on the efficacy, functionality, and total efficacy subscales compared with placebo in all attacks in both studies. Sumatriptan/naproxen treatment also provided significantly greater ease of use in 7 of the 8 attacks. Although tolerability was high in both treatment groups (over 90%), the placebo group was significantly less bothered by side effects in 6 of 8 attacks. Results from these 2 randomized, double-blind, placebo-controlled, multi-attack, crossover studies demonstrated the rapid and consistent restoration of patients' functioning, the consistent reduction in productivity loss, and high satisfaction ratings from patients treating multiple migraine attacks with S/NS using an early intervention approach.

Framework and systematic functional criteria for integrated work processes in complex assets: a case study on integrated planning in offshore oil and gas production industry

Improving the efficiency and cost-effectiveness of the oil and gas (O&G) production process is considered as a critical timely need. The core work processes in particular are targeted for considerable improvements. In this context, development related to integrated planning (IP) is seen as one of the major bases for developing collaborative work processes connecting offshore production and onshore support system. With feasible benefits, for instance, relating to reduction of non-working time, less work repetition, reduction of reduction in production losses, better resource utilisation, etc., a systematic and a complete IP system is today seen as an attractive solution for integrating complex operations and to work smarter. This paper, based on a case study from North Sea oil and gas production environment, describes the systematic functional criteria required as the basis for developing a fully functional IP system.

Evaluation of a multiprofessional rehabilitation programme for persistent musculoskeletal-related pain: Economic benefits of return to work

The aim of this study was to evaluate the economic consequences of an 8-week multiprofessional rehabilitation programme for patients with persistent pain. A group of 67 patients following the programme and a comparison group of 322 patients. The effect on return to work was estimated using 3 different methods: (i) a matched sample approach; (ii) regression analysis; and (iii) propensity score matching. The economic benefit of the programme was estimated as a reduction in production losses due to sick-leave. This benefit was compared with the actual cost of the programme. The benefit of the programme was estimated to be euro3,799-7,515 per treated patient and year. The total cost of the programme was estimated to be euro5,406 per patient. Based on these figures the total cost of the programme, including costs for patients remaining on sick-leave, had been recovered when the successfully rehabilitated patients had worked for 9-17 months. Any additional work after that yielded net economic benefits. Since other studies indicate that a large proportion of the patients working after one year also work after 3 and 6 years, we conclude that this multiprofessional rehabilitation programme for patients with persistent pain most likely generates substantial net economic gains.

Substantial sick-leave costs savings due to a graded activity intervention for workers with non-specific sub-acute low back pain

The objective of this study is to compare the costs and benefits of a graded activity (GA) intervention to usual care (UC) for sick-listed workers with non-specific low back pain (LBP). The study is a single-blind, randomized controlled trial with 3-year follow-up. A total of 134 (126 men and 8 women) predominantly blue-collar workers, sick-listed due to LBP were recruited and randomly assigned to either GA (N = 67; mean age 39 +/- 9 years) or to UC (N = 67; mean age 37 +/- 8 years). The main outcome measures were the costs of health care utilization during the first follow-up year and the costs of productivity loss during the second and the third follow-up year. At the end of the first follow-up year an average investment for the GA intervention of 475 euros per worker, only 83 euros more than health care utilization costs in UC group, yielded an average savings of at least 999 euros (95% CI: -1,073; 3,115) due to a reduction in productivity loss. The potential cumulative savings were an average of 1,661 euros (95% CI: -4,154; 6,913) per worker over a 3-year follow-up period. It may be concluded that the GA intervention for non-specific LBP is a cost-beneficial return-to-work intervention.

Development and application of a decision support tool for reduction of product losses in the food-processing industry

In food-processing industries, reduction of product losses is important for improving profitability and sustainability. This paper presents a decision support tool for analyzing the effects of planning decisions on the amount of product losses in the food-processing industry. We created a research framework to collect and analyze data, supporting the development of an Excel-based decision support tool that helps to evaluate different scenarios for the planning decisions and production parameters. The tool was developed in co-operation with and implemented in a real-life dairy plant, where the tool was able to reduce the planning-related losses by nearly 20%. But an equally important result is the insight gained on the interactions between processing, packaging, and intermediate storage. The framework and tool can easily be implemented in other situations.

Acute Peripheral Joint Injury: Cost and Effectiveness of Low-Field-Strength MR Imaging—Results of Randomized Controlled Trial

To assess prospectively if a short imaging examination performed with low-field-strength dedicated magnetic resonance (MR) imaging in addition to radiography is effective and cost saving compared with the current diagnostic imaging strategy (radiography alone) in patients with recent acute traumatic injury of the wrist, knee, or ankle. Institutional review board approval and informed consent were obtained. Patients with recent trauma of the wrist, knee, or ankle were randomized across two diagnostic strategies: radiography alone (reference group) or radiography followed by a short MR imaging examination (intervention group). Measures of effectiveness included the number of additional diagnostic procedures, time to last diagnostic procedure, and number of days absent from work. Measures of effectiveness were analyzed by using an exact Wilcoxon-Mann-Whitney test. Time to convalescence and quality of life were analyzed by using a t test. Cost analysis was performed from a societal perspective and analyzed by using a t test. Five hundred patients (207 women, 293 men; mean age, 34.8 years) with acute injury of the wrist, knee, or ankle were randomized. In the intervention group, quality of life for patients with knee injuries was significantly higher during the first 6 weeks, and time to completion of diagnostic work-up was significantly shorter (mean, 3.5 days for intervention group vs 17.3 days for reference group). The number of additional diagnostic procedures was significantly lower in the intervention group versus the reference group (nine vs 35, respectively) for patients with knee injuries. Patients with knee injuries showed the largest difference in costs (intervention group, 1820 [$1966]; reference group, 2231 [$2409]) owing to a reduction in productivity loss. Costs were higher in patients with wrist injuries and almost equal in patients with ankle injuries. All cost differences, however, were not significant. Compared with radiography, MR imaging in patients with acute wrist or ankle injuries is neither cost saving nor effective in expediting diagnostic work-up or improving quality of life. In patients with knee injuries, a short MR imaging examination shortens the time to completion of diagnostic work-up, reduces the number of additional diagnostic procedures, improves quality of life in the first 6 weeks, and may reduce costs associated with lost productivity.

Graded Exercise

Low back pain (LBP) is an important medical and social problem that can lead to disability for work and sick leave. Research has shown that a behaviour-oriented physical exercise intervention based on operant-conditioning principles has beneficial effects on return to work. Objective To determine the effects of a behaviour-oriented graded activity intervention for sick-listed workers with sub-acute non-specific LBP over a 12-month follow-up period. Method The study was carried out in the occupational health service department of the Royal Dutch Airlines (KLM). 134 workers, sick-listed due to LBP, were randomly assigned to either a graded activity group (n=67) or usual care group (n=67). The graded activity intervention can be described as a physical exercise programme, based on operant-conditioning behavioural principles, that is aimed at a safe and rapid return to work. Sick-leave data were obtained from the electronic database of the occupational health services and health care utilization data were collected by means of cost diaries. Results The graded activity group returned to work faster with a median of 54 days of sick leave compared to 67 days of sick leave in the usual care group. The graded activity intervention was effective from approximately 50 days of sick leave after randomization (hazard ratio 1.9; 95% confidence interval 1.2 to 3.1, p=0.01) and onwards. The differences between the groups in the number of recurrent episodes of sick leave due to LBP, the total number of days of sick leave due to LBP and due to all diagnoses were in favour of the graded activity group, although not statistically significant. No effects of the graded activity intervention were found for functional status or severity of pain. The differences between the groups in recurrent episodes of sick leave due to LBP, the total number of days of sick leave due to LBP, and the total number of days of sick leave due to LBP and other diagnoses, were in favour of the graded activity group, although not statistically significant. No effects of the graded activity intervention were found for functional status or severity of pain. An average investment for graded activity intervention of 475 Euro per worker with LBP may yield an average net savings of at least 999 Euro (95% CI: −1073; 3115) due to a reduction in productivity loss, although this saving is also not statistically significant. Conclusions This study demonstrates that the graded activity intervention is a valuable strategy for stimulating return to work of workers who are sick-listed due to LBP.

Parasitism by Campoletis flavicincta on Spodoptera frugiperda in corn

Parasitism by Campoletis flavicincta (Ashmead) (Hymenoptera: Ichneumonidae) on Spodoptera frugiperda (Smith) (Lepidoptera: Noctuidae) and consequent reduction of production losses were evaluated on caged corn plants in the field. Treatments consisted of plots infested with 0 (control), 15 and 30 pairs of C. flavicincta with egg masses per cage and plot infested without cage and liberation of the parasitoid. Parasitoid release was done when S. frugiperda larvae were three-day-old. Fifty corn plants (40%) per plot were collected seven days after infestation and S. frugiperda larvae present were reared in glass cups on an artificial diet. Number of S. frugiperda larvae was reduced by C. flavicincta but mortality of the pest and parasitoid sex ratio in laboratory were similar among treatments. Total progeny and female production from collected larvae were similar among densities of released parasitoid. Parasitism rate was higher on 30 than on 15 pairs of C. flavicincta. Damage on corn plants at seven and 14 days after S. frugiperda infestation had similar grades at 0, 15 or 30 C. flavicincta pairs and higher values than the plots without cage. Damage by S. frugiperda was lower at 30 C. flavicincta pairs after 21 days of infestation. Final stand, stand reduction by plant death and corn productivity were similar among treatments.