Sustainable Manufacturing Research Articles

Hydrodynamic and Temperature Profile Analysis in a Gas-Solid Fluidized Bed with Liquid Atomization to Convert Fructose to Value-Added Chemicals

Carbohydrates specified C6 sugars dehydrate to produce platform chemicals like 5-hydroxymethyl furfural and furfural that further oxidize to chemicals 2,5-diformyl furan and 2,5-furan dicarboxylic acid. Here we propose a gas-phase in which a two-fluid nozzle atomizes a 0:1 ▪ fructose in water solution into a fluidized bed of Mo–V–▪/▪. However, the imperfect interaction between droplet and catalyst increases the agglomeration, which destroys the heat transfer efficiency and hydrodynamic stability. We evaluated the temperature and gas residence time distribution in catalytic bed to improve reaction and process performance by modifying the bed temperature, bed height, and gas velocity. A high mass of catalyst (>▪) degrades fructose and reduces the selectivity. At ▪ temperature distributes homogeneously within bed and with time on process it shifts toward higher values. Velocity in the range of ▪ to ▪ yield product with the highest selectivity (16%). These results demonstrate the potential of optimizing gas-phase catalytic processes to improve the selective production of platform chemicals from carbohydrates, supporting more sustainable chemical manufacturing.

Application of 3D printing across various fields to enhance sustainable manufacturing

Application of 3D printing across various fields to enhance sustainable manufacturing

Sustainable manufacturing of 3D-Printed cyclic olefin copolymer coversheets with gahnite for enhanced silicon photovoltaic efficiency

Sustainable manufacturing of 3D-Printed cyclic olefin copolymer coversheets with gahnite for enhanced silicon photovoltaic efficiency

Optimization of CNC Turning Operation Parameters for H-13 Tool Steel Towards Sustainable Manufacturing

Optimization of CNC Turning Operation Parameters for H-13 Tool Steel Towards Sustainable Manufacturing

The impact of material selection and design on the environment in the process of making press tools for garment hanging products in sustainable manufacturing

The impact of material selection and design on the environment in the process of making press tools for garment hanging products in sustainable manufacturing

Robotic assistants for the rehabilitation of communication disorders in children: A proposal based on MTO manufacturing for developing countries

Language is fundamental to human communication, allowing individuals to express and exchange ideas, thoughts, and emotions. In early childhood, some children experience communication disorders that impede their ability to articulate words correctly, posing significant challenges to their learning and development. This issue is exacerbated in developing countries, where limited resources and a lack of technological tools hinder access to effective speech therapy. Traditional speech therapy remains vital, but the latest technological advancements have introduced robotic assistants to enhance therapy for communication disorders. Despite their potential, these technologies are often inaccessible in developing regions due to high production costs and a lack of sustainable manufacturing models. For these reasons, this paper presents “FONA,” a robotic assistant that employs rule-based expert systems to provide tactile, auditory, and visual stimuli. FONA supports children aged 3 to 6 in speech therapy by delivering exercises such as syllable production, word formation, and pictographic storytelling of various phonemes. Notably, FONA was successfully tested on children with cochlear implants, reducing the number of sessions required to produce isolated phonemes. The paper also introduces an innovative analysis of the Make To Order (MTO) manufacturing system for producing FONA in developing countries. This analysis explores two key perspectives: collaborative networks and entrepreneurship, offering a sustainable production model. In a pilot experiment, FONA significantly improved children’s attention spans, increasing the period by 17 min. Furthermore, the economic analysis demonstrates that producing FONA through collaborative networks can significantly reduce costs, making it more accessible to institutions in developing countries. The findings suggest that the project is viable for a five-year period, providing a sustainable and effective solution for addressing communication disorders in children.

Innovative Electrostatic Precipitator Solutions for Efficient Removal of Fine Particulate Matter: Enhancing Performance and Energy Efficiency

The removal of particulate matter (PM) from air streams is essential for advancing environmental technologies and safeguarding public health. This study explores the performance of an electrostatic precipitator (ESP) in eliminating fine and ultra-fine PM under varied experimental conditions. It uniquely examines the influence of PM size and feed rate on ESP removal efficiency. The system’s use of low voltages enhances energy sustainability, while its innovative design improves corona discharge, leading to significant reductions in fine and ultra-fine PM emissions. Plants using electrical devices are increasingly being incorporated into material processing lines to reduce pollution in the surrounding work area, as well as to collect particle emissions in the atmosphere. It is also possible to recycle some raw materials in this way with low energy consumption. This cleaning technology increases the added value of industrial equipment, which affects its competitiveness and its impact on sustainable manufacturing. The experimental results indicate a steady electrostatic field voltage of 15.1 kilovolts, with an airflow maintained at 0.8 m/s through a doser at 2.5 bar, eliminating the need for a fan. The PM feed rate varied between 2 and 20 mm/h, with six trials conducted to ensure the data were consistent. Preliminary studies devoid of ESP intervention demonstrated little PM removal, since buildup on the chamber walls distorted the results. The installation of the ESF markedly enhanced the removal efficiency, achieving up to 95.5%. Further analysis revealed that ESP performance depended on PM concentration in the agglomeration chamber, achieving a clearance rate exceeding 98% under optimal conditions. Fine PM (0.35 to 8.7 µm) was more efficiently removed than ultra-fine PM (0.2 to 0.35 µm). The highest removal efficiency was observed at a feed rate of 0.962 mg/s, while the lowest occurred at 0.385 mg/s. A strong positive correlation between particle concentration and removal efficiency (Pearson value up to 0.829) was observed, particularly at feed rates of 0.128, 0.641, and 1.283 mg/s. The study’s findings confirm that the ESP is highly effective in removing particulate matter, particularly fine and ultra-fine particles, with an optimal feed rate, significantly enhancing the system’s performance.

Critical machining parameters for large aircraft casing production considering the influence of clamping systems

AbstractIn recent years, there has been a notable initiation or acceleration in the production of new aeronautical engines. This surge is coupled with a global commitment to reducing emissions and mitigating noise generated by gas turbines used in aeronautical applications. A critical component in this context is the aeronautical casing. The manufacturing process is intricate and time-consuming, compounded by the complexity of the clamping system, which poses a significant challenge to productivity. This study undertakes a comprehensive analysis of the critical variables essential for the optimal manufacturing of a zero-defects large-scale casing. The examination encompasses design criteria, raw materials, constraints related to clamping systems and tooling, and process monitoring. Ultimately, the exploration extends to the examination of more sustainable manufacturing techniques. To facilitate this, a case study involving the fabrication of a life-size aeronautical casing is undertaken.

Towards sustainable manufacturing: unpacking green practices’ impact on environmental performance in Pakistan

Towards sustainable manufacturing: unpacking green practices’ impact on environmental performance in Pakistan

The Influence of Selected Parameters of Recycled Polyvinyl Butyral on the Sustainable Filament Extrusion Process

In recent years, sustainability has permeated nearly every aspect of our lives, and the manufacturing sector is no exception. The terms “sustainable manufacturing” and “zero-waste manufacturing” are now part of our everyday vocabulary. This study, which explores the influence of key parameters on the filament extrusion process using recycled polyvinyl butyral (PVB), which is an amorphous polymer commonly obtained from the glass recycling industry, has significant practical implications. By determining the optimal conditions for the extrusion process, we can enhance the mechanical properties of the produced PVB filament yarns and their printability. As a result of identifying errors, optimizing the process, and eliminating the resulting shortcomings, a fiber made of PVB material with a diameter of 1.75 mm (±0.06 mm) was created that can be used in most FDM devices. The length of the created fiber was approx. 20 m, and in the presentation of the results, it will be used for printing samples, adhesion tests to the printing mat, shrinkage tests, and tensile tests of the fiber. After removing all the shortcomings, the ideal extrusion temperature was at 155 °C. This temperature was verified using microscopic cross-sections, and deformations or changes were observed in their cross-sections. The deviation of the material currently undergoing testing for the adhesion of PVB to various types of print beds, which was found suitable for use in FFF devices, was 1.75 −0.25/+0.25. This, in turn, can significantly expand the application of these materials in additive manufacturing, thereby making a substantial contribution to the advancement of sustainable manufacturing.

Impact of smart factory adoption on manufacturing performance and sustainability: an empirical analysis

PurposePrevious studies have focused on explaining the developmental paths and the relevant skills necessary for smart factories, based on an extensive review of the literature. Unfortunately, there is a deficit of empirical analyses that present an in-depth overview of smart factory development. Although the literature supports the benefits of smart factories, it remains unclear whether there should be government intervention (GI) to facilitate or regulate such adoption. This study will provide an in-depth empirical analysis of smart factory adoption (SFA) and its role in manufacturing performance (MP) and sustainable manufacturing (SM).Design/methodology/approachThis study used non-probability convenience and referral sampling techniques for data collection. This approach considered production managers from each company that participated in the survey questionnaire; thus, each production manager represented one firm. A total of 240 managers from several manufacturing companies participated in the study. This study employed direct and moderating hypotheses tested using PROCESS Macro, which Andrew Hayes developed for SPSS.FindingsThe study identified three fundamental elements of a smart factory: manufacturing big data (MBD), process automation (PA) and supply chain integration (SCI) and analyzed them individually to see how they affect MP. According to the results, building a smart factory has positive and significant impacts on MP and SM. Furthermore, this study explores the role of GI in promoting smart factory deployment for both production performance and sustainable production. The study found that GI did not have a significant moderating effect but did have a positive relationship with SM.Research limitations/implicationsThis study contributes to the literature on smart factories by examining the impact of SFA on MP and SM. This provides a more comprehensive overview of the potential benefits of smart factories across various aspects, such as the application of big data, adoption of automation technology and integration of the supply chain. This study suggests that managers and decision-makers consider investing in smart factory implementation to improve factory productivity and enhance sustainability. Policymakers and government officials can promote the adoption of smart factories by providing incentives, funding, and resources to manufacturing firms.Originality/valueThere is a scarcity of research measuring the actual performance of manufacturing firms that have already adopted smart factories, and this study seeks to address this gap in the literature. This study focuses on the implementation of manufacturing big data, process automation and supply chain integration and how the adoption of these technologies improves MP and provides a SM environment by conducting a real-time study of manufacturing organizations. This study presents an initial effort to explore the role of government involvement in promoting smart factories.

Sustainability assessment of additive manufacturing end-of-life material management

Additive manufacturing (AM) methods enable complex, customized, and on-demand production of many products from different material types across various industries. The growing demand for flexible and more sustainable manufacturing solutions places AM in the mix of processes considered for non-commodities. However, AM processes also present unintentional environmental releases in end-of-life (EoL) material management, compromising overall sustainability. Data availability to assess the sustainability of individual EoL material management from individual AM processes is limited. Even so, EoL materials generated across AM practices frequently overlap, supporting high-level assessment as an alternative approach. Therefore, a holistic AM EoL material management sustainability analysis was completed using a customized list of efficiency, environmental, energy, and economic indicators from the Gauging Reaction Effectiveness for the Environmental Sustainability of Chemistries with a multi-Objective Process Evaluator (GREENSCOPE) methodology. Subsequently, this assessment identified low material recycling rates and high energy costs in some EoL material management processes, such as incineration and recovery. Subsequently, a trade-off analysis was performed to determine process modification opportunities, including implementing recycling to reduce the amount of hazardous waste at the expense of additional energy and cost investment. The AM EoL-specific sustainability analysis serves as a resource to offer insights and empower policymakers and stakeholders to enhance pollution prevention strategies and optimize the existing EoL material management processes.

An expert system based decision-making framework for benchmarking industry in sustainable manufacturing

PurposeThe purpose of this study is to evaluate and enhance sustainable manufacturing practices across various industries, focusing on environmental, economic and social dimensions, to promote a comprehensive understanding and implementation of sustainability, thereby improving overall industry performance and fostering long-term ecological and economic health.Design/methodology/approachThe study uses multi-criteria decision-making-multivariate analysis technique to examine sustainable manufacturing practices (SMPs) in the Indian manufacturing sector. It identifies 11 SMP criteria through literature review and expert recommendations. Data are collected through questionnaires, expert committees and interviews. The study focuses on four key industries: automobile, steel, textile and plastic. Techniques like principal component analysis (PCA), technique for order preference by similarity to ideal solution (TOPSIS) and complex proportional assessment (COPRAS) are used to rank and assess performance.FindingsThe Indian automobile industry has shown the most effective SMPs compared to steel, textile and plastic sectors. The automobile sector is the benchmark for sustainable measures, emphasizing the importance of green practices for environmental, social and economic performance. Recommendations extend beyond the automobile sector to cement, electronics and construction.Practical implicationsThe research emphasizes the importance of SMPs across various industries, focusing on economic, environmental and social considerations. It advocates for a holistic approach that enhances resource efficiency and minimizes ecological footprint.Originality/valueThe study uses ranking methods like PCA-integrated TOPSIS and COPRAS to evaluate performance in different industries, focusing on the benchmarked automobile sector. The research offers valuable insights and advocates for the widespread adoption of sustainable policies beyond the studied sectors.

Retraction Note: Sustainable manufacturing intelligence: pathways for high-quality and energy efficient economic growth

Retraction Note: Sustainable manufacturing intelligence: pathways for high-quality and energy efficient economic growth

Filtering ‘3–2’ industrial symbiosis networks at a carbon-intensive cluster in a small island developing state to reuse CO2 and water

Small island developing states (SIDS) face internal and external pressures for more sustainable manufacturing e.g., economic and ecological water provision, and anti-carbon leakage tariffs. As SIDS have special developmental challenges, locally appropriate strategies are needed. In one of these SIDS, Trinidad and Tobago, is a carbon-intensive industrial cluster of global standing, the Point Lisas Industrial Estate (PLIE). So, to investigate ‘3–2’ industrial symbiosis (IS) on the PLIE, a simple enterprise input-output MILP model of a representative IS network was developed. Different quality wastewater streams and high-purity process CO2 from ammonia processes were selected as materials to be reused in: existing petrochemical plants, a mineral carbonate factory and a propylene carbonate plant. To filter the IS relations, economic and environmental objectives were set for each material. Combining economic objectives left a tri-objective problem, which was resolved with ε-constraint optimization and multi-criteria decision-making methods. Kleinberg's hub and authority scores were found to give beneficial insight into the solved IS networks. Potential revenue-generating opportunities were uncovered for sharing and reusing water and process CO2. The results suggest adding two proposed carbonate factories could increase the mass of CO2 reused in the cluster by 10.4 % and mitigate releasing 5 Tg/y of rejected desalination brine.

Sustainable additive manufacturing supply chains with a plithogenic stakeholder analysis: Waste reduction through digital transformation

The Additive Manufacturing (AM) industry is of paramount importance as means of personalized design capabilities by rapid prototyping, using exact amount of required materials avoiding waste, and applying Industry 4.0 technologies with digital transformation ability. The characteristics of AM are regarded as the prerequisites for sustainability in the manufacturing industry. However, there are limited papers discussing the stakeholders and sustainability objectives in a single comprehensive analysis. Hence, the purpose of this research is to identify the degree of each stakeholder to achieve the objective of sustainability in AM supply chain by proposing a novel Plithogenic Fuzzy MACTOR approach. Results reveal that the customers are in triggering position to shape entire AM supply chain as the demand generators. Workforce is a significant player in the AM supply chain by creating the design, manufacturing, marketing, and communicating to provide the collaborations in this business segment. Academia positions here a supportive role to enable the whole supply chain members in terms of delivering technological advancements, training people, and providing the workforce. The AM manufacturers and material / software / printer suppliers are the key players leading to the supply chain by producing the main business products. Thus, a practitioner can interpret its position in the AM supply chain and understand the requirements of sustainability points in detail. Besides, this study provides a theoretical contribution to the literature by extending the MACTOR analysis with Plithogenic sets via including a different uncertainty measure.

Machinability performance of bio-degradable hybrid nano-cutting fluid for sustainable manufacturing: analytical and soft computing modelling

Machinability performance of bio-degradable hybrid nano-cutting fluid for sustainable manufacturing: analytical and soft computing modelling

Special issue on thin-films for sustainable manufacturing

Sustainable manufacturing is the creation of products using technologies capable of decoupling the factors that may adversely affect the environment. One such technology is thin film coating, extensively used for various commercial applications. Achieving energy and resource efficiency, cost reduction, short process chain of manufacturing and long life for tools and products are some of the benefits of using thin film coatings. This technology significantly contributes to strengthening all three pillars, that is, environment, economy and society of sustainability. This special issue aims to highlight some of the critical application areas of thin film coatings under sustainable manufacturing, focusing on machining.

Leveraging Industry 4.0 for Sustainable Manufacturing: A Quantitative Analysis Using FI-RST

The Fourth Industrial Revolution, also known as Industry 4.0, which is the intensified digitalization and automation in industry, embraces cyber–physical systems, the Internet of Things (IoT), and artificial intelligence, among others. This study utilizes Fuzzy Integration–Rough Set Theory (FI-RST) analysis to quantify the impacts of the imperative Industry 4.0 technologies for manufacturing firms located in Fujian Province, China, namely, Manufacturing Execution Systems (MES), the Industrial Internet of Things (IIoT), and Additive Manufacturing (AM), on the sustainable development performance of firms. The findings of the study indicate that these technologies greatly improve the effectiveness of the utilization of resources, reduce the costs of operations, and reduce the impact on the environment. In addition, they have a favorable influence on social considerations, such as preserving the well-being of employees and the outcome of training programs. This research work has convincingly provided an underlying strategic adoption of these technologies for sustainability production by raising important insights that could be valuable for industry managers and policymakers, especially those seeking sustainability at the global level.

A framework to assess the effectiveness index (EI) of the Indian SMEs to integrate lean and sustainability through combined fuzzy logic and systems approach

PurposeTo become a sustainable lean manufacturing (LM) system, an organization must be first distinctly cognizant of the terms “lean” and “sustainability” as they relate to the state of affairs of their particular industry and business. Next, the organization must identify and acquire the necessary qualities it needs to become sustainable in lean philosophy and its practices in the organization. The LM paradigm has been a top priority for many businesses; thus, this article is based on actual research done in Indian small and medium scale organizations to see how widely it is understood and implemented.Design/methodology/approachA framework was developed based on literature review and academic research. A preliminary analysis of a small number of small and medium-sized enterprises (SMEs) that, conceptually, summarizes and demonstrates the concerted efforts that a company may undertake to increase its leanness. This conceptual model was employed to create a questionnaire that was administered to survey the SMEs of India. The information gathered through this questionnaire was analyzed using the model developed by the researchers. Then fuzzy logic and systems approach were used to find out the effectiveness index (EI) of the organization.FindingsThe EI for system leanness at different organizational levels within an organization is determined using fuzzy logic and systems approach for 48 SMEs in different clusters. The average EI of the system was found to be 0.336 on a scale of 0–1 which indicates that the current state of lean implementation and its sustainability is very low and poor in Indian SMEs. This article outlines the key model components and describes how they were applied to analyze the data gathered from an industry study.Research limitations/implicationsThe research aims to make lean continuously sustainable by surfacing and eliminating the wastes in the Indian SMEs whenever it appears rather than using it as a cleaning tool. The present study was focused on India’s southern industrial areas and it was difficult to gather the information around the country due to its diverse industrial culture and geography. Hence, more research and the comparative study of the same that takes into account the various regions of the nation’s industrial lean behavior can be conducted.Practical implicationsThe generalized sustainable lean framework analyzed using fuzzy logic and systems approach gives the current effectiveness of the leanness in SMEs of south India. This model can be effectively implemented in other areas of the nation to identify the scenario of lean and its sustainability and a final comprehensive model can be developed.Originality/valueThere is a dearth of comprehensive studies on the assessment of sustainability of the lean philosophy in Indian SMEs. With the help of combined fuzzy logic and systems approach, the model developed in this study evaluates the sustainability of the lean methodology using the EI used in SMEs by taking into account both the lean and sustainability factors as well as enablers like customer satisfaction, ethics, innovation and technology.