Sustainable Manufacturing Process Research Articles

Development of a Green and Sustainable Manufacturing Process for a Key Intermediate to Nemtabrutinib (MK-1026): Sequential Deprotonation–Lithiation as a Batch–Flow Process

Development of a Green and Sustainable Manufacturing Process for a Key Intermediate to Nemtabrutinib (MK-1026): Sequential Deprotonation–Lithiation as a Batch–Flow Process

Towards artificial intelligence empowered performance enhancement of EDM process using nano-graphene mixed bio-dielectric supporting the carbon neutrality and sustainable development

The growing population with every passing day sets an alarming situation with respect to the conservation climate protocols. The increasing needs of society also demand a significant enhancement in the manufacturing capacity to augment the situation. However, it's a stringent requirement of the hour to propose sustainable and clean manufacturing processes to realize the goal of carbon neutrality to support a healthy life on the earth. Specifically, the processes that are energy intensive like electric discharge machining (EDM) are of serious concern regarding sustainability viewpoint. The role of the said process cannot be essentially eliminated as advent of new materials of superior characteristics demand the application of EDM for accurate cutting of intricate profiles. Nevertheless, the commonly used oil-based dielectric (kerosene) in EDM releases aerosol, deposit particles, oxides of carbon (CO2 & CO), thus contributing to the environmental contamination. It is pertinent to mention that industries are compelled to tune their processes to achieve the goals of Net-Zero. Therefore, this study thoroughly investigates the potential of nano-graphene mixed rice bran oil to make the EDM process cleaner and sustainable which has never been investigated so far. Moreover, the process has been successfully modeled using artificial neural network (ANN) and optimized by non-dominated sorting genetic algorithm-II (NSGA-II) which is another novel aspect of this study as it eradicates the need of extensive experimentation. Experimentation has been performed via Taguchi's experimental strategy followed by a detailed explanation of the findings based on process physics. In comparison to the traditional dielectric an improvement of 98.8% in material removal rate (MRR) and 93.9% reduction in specific energy consumption (SEC) are realized if the said novel combination is applied without compromising the quality. CO2 emissions determined for both rice bran oil and kerosene oil have revealed that rice bran oil provides 99.96% lesser CO2 emission in comparison to its counterpart.

Process optimization for microfluidic preparation of liposomes using food-grade components

This study explores the potential for optimizing a sustainable manufacturing process that maintains the essential characteristics of conventional liposomes using food-grade solvents and components. The focus was comparing the physicochemical, morphological, and interfacial properties of liposomes produced with these food-grade ingredients to those made by conventional methods. It was found that there was no significant difference in particle size (195.87 ± 1.40 nm) and ζ-potential (−45.13 ± 0.65 mV) between liposomes made from food-grade and conventional materials. The manufacturing process for liposomes, utilizing food-grade solvents and components, was optimized through the application of Plackett-Burman design and response surface methodology. This approach helped identify key parameters (soy lecithin, β-sitosterol, W/O ratio) and their optimal values (3.17 g, 0.25 g, 1:2.59). These findings suggest that it is possible to enhance the use of liposomes as an effective and safe delivery system in the food industry, adhering to the strict guidelines set by regulatory agencies.

Digital Cellulose: Recent Advances in Electroactive Paper

With the increasing global demand for net-zero carbon emissions, actions to address climate change have gained momentum among policymakers and the public. The urgent need for a sustainable economy is underscored by the mounting waste crisis in landfills and oceans. However, the proliferation of distributed electronic devices poses a significant challenge due to the resulting electronic waste. To combat this issue, the development of sustainable and environmentally friendly materials for these devices is imperative. Cellulose, an abundant and CO2-neutral substance with a long history of diverse applications, holds great potential. By integrating electrically interactive components with cellulosic materials, innovative biobased composites have been created, enabling the fabrication of bulk electroactive paper and the establishment of new, potentially more sustainable manufacturing processes for electronic devices. This review explores recent advances in bulk electroactive paper, including the fundamental interactions between its constituents, manufacturing techniques, and large-scale applications in the field of electronics. Furthermore, it addresses the importance and challenges of scaling up production of electroactive paper, highlighting the need for further research and development.

Glutamate production from aerial nitrogen using the nitrogen-fixing bacterium Klebsiella oxytoca

Glutamate is an essential biological compound produced for various therapeutic and nutritional applications. The current glutamate production process requires a large amount of ammonium, which is generated through the energy-consuming and CO2-emitting Haber–Bosch process; therefore, the development of bio-economical glutamate production processes is required. We herein developed a strategy for glutamate production from aerial nitrogen using the nitrogen-fixing bacterium Klebsiella oxytoca. We showed that a simultaneous supply of glucose and citrate as carbon sources enhanced the nitrogenase activity of K. oxytoca. In the presence of glucose and citrate, K. oxytoca strain that was genetically engineered to increase the supply of 2-oxoglutarate, a precursor of glutamate synthesis, produced glutamate extracellularly more than 1 g L−1 from aerial nitrogen. This strategy offers a sustainable and eco-friendly manufacturing process to produce various nitrogen-containing compounds using aerial nitrogen.

Harnessing the dual nature of W. coagulans for sustainable production of biomaterials and development of functional food.

Bacillus coagulans, recently renamed Weizmannia coagulans, is a spore-forming bacterium that has garnered significant interest across various research fields, ranging from health to industrial applications. The probiotic properties of W. coagulans enhance intestinal digestion, by releasing prebiotic molecules including enzymes that facilitate the breakdown of not-digestible carbohydrates. Notably, some enzymes from W. coagulans extend beyond digestive functions, serving as valuable biotechnological tools and contributing to more sustainable and efficient manufacturing processes. Furthermore, the homofermentative thermophilic nature of W. coagulans renders it an exceptional candidate for fermenting foods and lignocellulosic residues into L-(+)-lactic acid. In this review, we provide an overview of the dual nature of W. coagulans, in functional foods and for the development of bio-based materials.

Optimal Sustainable Manufacturing for Product Family Architecture in Intelligent Manufacturing: A Hierarchical Joint Optimization Approach

As consumers and governments prioritize cost-effectiveness and ecological sustainability, the limitations of traditional manufacturing paradigms become apparent in the context of constrained resources. The adverse effects of these paradigms on the environment and society hinder the achievement of a sustainable product life cycle. Intelligent manufacturing processes offer a solution by efficiently gathering meaningful data, such as usage and product recycling information, from previous product generations to enhance product design and subsequent sustainable manufacturing processes (SMPs). Modular product family architecture (PFA) design holds promise in promoting product sustainability and addressing diverse consumer needs. PFA design and SMPs are inherently interconnected within intelligent manufacturing frameworks. This paper aims to integrate the decision-making processes underlying PFA with SMPs. We model integrated PFA and SMP decisions as a Stackelberg game, which involves hierarchical joint optimization (HJO) for assessing product modularity and sustainable manufacturing fulfillment. We develop a bilevel 0–1 integer nonlinear programming model to represent the HJO decision-making process and propose a nested genetic algorithm (NGA) to solve the HJO problem. A case study with a laptop is conducted to validate the feasibility and potential of the proposed HJO model for joint optimization problems in PFA design and SMPs.

Biocatalysis for Green Synthesis: Exploring the Use of Enzymes and Microorganisms as Catalysts for Organic Synthesis, Highlighting Their Advantages over Traditional Chemical Catalysts in Terms of Selectivity, Efficiency, and Environmental Impact

This study explores the use of microorganisms and enzymes as catalysts for organic synthesis, highlighting the advantages of these catalysts over conventional chemical catalysts in terms of selectivity, efficiency, and environmental effect. This study explains the major advantages of biocatalysis, such as its high selectivity, mild reaction conditions, efficiency, low environmental impact, and compatibility with renewable feedstocks, by looking at several case studies and experimental results. The importance of biocatalysis in advancing environmentally friendly and sustainable manufacturing processes is emphasized.

Big data analytics-artificial intelligence and sustainable performance through green supply chain practices in manufacturing firms of a developing country

Purpose This study aims to examine the role of big data analytics (BDA) powered by artificial intelligence (AI) in improving sustainable performance (SP) through green supply chain collaboration (GSCC), sustainable manufacturing (SM) and environmental process integration (EPI). Design/methodology/approach Data was collected from 249 supply chain professionals working at various manufacturing firms, and hypotheses were tested through a quantitative method using PLS-SEM with the help of SmartPLS version 4 to validate the measurement model. Findings This study identified that BDA-AI significantly and positively affects GSCC, SM and EPI. Similarly, the results showed that GSCC significantly and positively affects SP. At the same time, SM and EPI have an insignificant effect on SP. The GSCC found a significant relationship between BDA-AI and SP for mediation. However, SM and environmental performance integration did not mediate the relationship between BDA and AI and SP. Originality/value This research evaluated a second-order model and tested SP in conjunction with the dynamic capability theory in the manufacturing industry of Pakistan. Therefore, this research could be beneficial for researchers, manufacturers and policymakers to attain sustainable goals by implementing the BDA-AI in the supply chain.

Failure mechanics of fused filament fabricated nylon/carbon-reinforced composites

AbstractThis work focuses on understanding the failure mechanisms of nylon-reinforced chopped carbon fiber (Onyx) composite and its reinforcement with carbon fiber printed using different infill patterns, i.e., solid fill, honeycomb, and triangular via fused filament fabrication (FFF) to enhance the sustainable manufacturing processes. The solid fill with carbon fiber reinforcement showcased a maximum tensile strength and flexural strength of ~ 300 MPa and ~ 22 MPa which were more than twice that of non-reinforced composites with fiber pull-out and layer debonding as predominant failure mechanisms. On the other hand, non-reinforced samples indicated matrix debonding as predominant failure behavior. The solid fill samples illustrated a lower failure mechanism owing to their higher bonding between each layer with limited voids whereas honeycomb and triangular samples failed faster due to the high number of voids limiting their bonding behavior. Furthermore, the load transfer capacity of honeycomb and triangular infill composites was limited due to reduced adhesion between the layers. Although the mechanical properties of onyx-based composites do not make them suitable for structural applications, the fused filament fabrication approach makes onyx a potential material for internal non-loading structures with complex geometries.

Allulose‐crystallized fruits: Effect of non‐thermal air‐drying and UV‐A light dehydration of osmotic solutions

AbstractThe purpose of this research was to confirm the suitability of allulose to produce crystallized fruits under nonthermal conditions and the suitability of UV‐A light dehydration to concentrate the osmotic solutions. Mangoes and apples were subjected to osmotic drying with either sucrose or allulose, which was followed by an air‐drying step at room temperature to further concentrate the crystallized fruits. There was no significant difference in the dehydration kinetics parameters between the two sugars in each crystallized fruit. Color evaluations showed that allulose was able to better preserve the color of the original raw fruits in the final crystallized samples. Electron microscopy images suggested a more uniform diffusion of allulose as compared to sucrose for both fruits. Similarly, liquid chromatography and infrared spectroscopy analyses confirmed the successful absorption of both sugars into both fruits, with allulose having a final higher concentration in both mango and apple (51.7 ± 5.6% and 70.8 ± 7.7% w/w, respectively) as compared to sucrose (48.6 ± 2.9% and 58.3 ± 3.4% w/w, respectively). UV‐A light dehydration showed to be able to increase the recovery of the sugars from osmotic solutions better than in conditions without UV‐A light exposure. When only air flow was used, it was possible to remove 85.3 ± 4.6% and 78.6 ± 0.6% of the original moisture in the sucrose and allulose solutions, respectively. In contrast, under UV‐A light dehydration, the percentage of the original water removed from the sucrose and allulose solutions was 95.2 ± 1.8% and 83.1 ± 1.9%, respectively.Practical applicationsThere is an increasing trend toward producing foods that are healthier for the general population. The use of rare sugars like allulose offers a promising alternative to accomplishing this. In addition, it has become imperative to develop processes that are more sustainable. The use of air‐drying at room temperature can represent an effective approach to develop more sustainable food manufacturing processes. More specifically, the use of UV‐A light dehydration (which is a non‐thermal food dehydration technique) for the recovery of solutes or the concentration of osmotic solutions can also represent an effective aid in this type of processes.

Evolution of a Green and Sustainable Manufacturing Process for Belzutifan: Part 5─Chemoenzymatic Diastereoselective Fluorination/DKR

Evolution of a Green and Sustainable Manufacturing Process for Belzutifan: Part 5─Chemoenzymatic Diastereoselective Fluorination/DKR

Evolution of a Green and Sustainable Manufacturing Process for Belzutifan: Part 6─Development of a Nucleophilic Aromatic Substitution in Water

Evolution of a Green and Sustainable Manufacturing Process for Belzutifan: Part 6─Development of a Nucleophilic Aromatic Substitution in Water

Evolution of a Green and Sustainable Manufacturing Process for Belzutifan: Part 1─Process History and Development Strategy

Evolution of a Green and Sustainable Manufacturing Process for Belzutifan: Part 1─Process History and Development Strategy

Advancing 3D Printing through Integration of Machine Learning with Algae‐Based Biopolymers

AbstractThe integration of machine learning (ML) with algae‐derived biopolymers in 3D printing is a burgeoning area with the potential to revolutionize various industries. This review article delves into the challenges and advancements in this field, starting with the critical problem it addresses the need for sustainable and efficient additive manufacturing processes. Algae‐based biopolymers, such as alginate and carrageenan, are explored for their viability in 3D printing, highlighting their environmental benefits and technical challenges. The role of ML in enhancing material selection, predictive modeling, and quality control is examined, showcasing how this synergy leads to significant improvements in 3D printing processes. Key findings include the enhanced mechanical properties of algae‐based biopolymers and the optimization of printing parameters through ML algorithms. Examples like the use of Spirulina in creating a range of materials and the application of carrageenan in bone tissue engineering are discussed. The conclusion underscores the transformative impact of combining ML with algae‐based biopolymers in 3D printing, paving the way for innovative, sustainable solutions in additive manufacturing. Despite existing challenges, this integration holds promise for a future of advanced, eco‐friendly manufacturing techniques.

Evolution of a Green and Sustainable Manufacturing Process for Belzutifan: Part 3─Development of a Scalable Enzymatic Oxidation Process

Evolution of a Green and Sustainable Manufacturing Process for Belzutifan: Part 3─Development of a Scalable Enzymatic Oxidation Process

Evolution of a Green and Sustainable Manufacturing Process for Belzutifan: Part 4─Applications of Process Analytical Technology in Heterogeneous Biocatalytic Hydroxylation

Evolution of a Green and Sustainable Manufacturing Process for Belzutifan: Part 4─Applications of Process Analytical Technology in Heterogeneous Biocatalytic Hydroxylation

Evolution of a Green and Sustainable Manufacturing Process for Belzutifan: Part 2─Development of a Scalable Nickel-Catalyzed Sulfonylation

Evolution of a Green and Sustainable Manufacturing Process for Belzutifan: Part 2─Development of a Scalable Nickel-Catalyzed Sulfonylation

Synthesis and Characterization of Cellulose Microfibril-Reinforced Polyvinyl Alcohol Biodegradable Composites.

The pursuit of an environmentally sustainable manufacturing process requires the substitution of less damaging and recyclable solutions for harmful reagents. This study aims to assess the effectiveness of using cellulose microfibrils synthesized via different hydrolysis reactions as reinforcing agents in polyvinyl alcohol (PVA) at varying concentrations. The investigation explores the morphology, thermal properties, and chemical behavior of the cellulose particles. The cellulose microfibrils (CMFs) produced using citric acid exhibited the highest yield and aspect ratio. Notably, particles from organic acids demonstrated greater thermal stability, with oxalic acid-derived particles displaying the maximum thermal degradation temperature. Subsequently, cast films of PVA reinforced with the cellulose microfibrils underwent comprehensive analyses, including Fourier transfer infrared (FTIR) spectroscopy, thermal degradation temperature (Td), differential scanning calorimetry (DSC), and tensile strength tests. The thermal behavior of cast films experienced notable changes with the addition of cellulose particles, evidenced by increased melting and crystallinity temperatures, along with a rise in the degree of crystallinity. The incorporation of cellulose particles led to a substantial improvement in mechanical properties. Films containing CMF displayed higher Young's modulus, and the sample incorporating 5% CMF derived from citric acid exhibited the most significant increase in modulus.

Identifying and charactering a 4-aminobutyryl-CoA ligase for the production of butyrolactam

Butyrolactam, a crucial four-carbon molecule, serves as building block in synthesis of polyamides. While biosynthesis of butyrolactam from renewable carbon sources offers a more sustainable approach, it has faced challenges in achieving high product titer and yield. Here, an efficient microbial platform for butyrolactam production was constructed by elimination of rate-limiting step and systematic pathway optimization. Initially, a superior 4-aminobutyryl-CoA ligase was discovered and characterized among six acyl-CoA ligases from different sources, which greatly improved the pathway efficiency. Subsequent optimizations were implemented to further enhance butyrolactam production, including promoter engineering, the elimination of competing pathways, transporter engineering and improving the availability of precursors. There efforts resulted in achieving approximately 2 g/L butyrolactam in shake flask experiments. Finally, the biosynthesis of butyrolactam was scaled up in a 3-L bioreactor in 84 hours, resulting in a significantly increased production of 45.2 g/L, with a carbon yield of 0.34 g/g glucose. This study highlights the construction of a microbial platform with the capability to achieve elevated levels of butyrolactam production and unlocks its potential in sustainable manufacturing processes.