Optimization of the Pultrusion process

Manufacturing processes need permanently to innovate and optimize because any can be susceptible to continuous improvement. Innovation and commitment to the development of these new solutions resulting from existing expertise and the continuing need to increase productivity, flexibility and ensuring the necessary quality of the manufactured products. To increase flexibility, it is necessary to significantly reduce set-up times and lead time in order to ensure the delivery of products ever faster. This objective can be achieved through a normalization of the pultrusion line elements. Implicitly, there is an increase of productivity by this way. This work is intended to optimize the pultrusion process of structural profiles. We consider all elements of the system from the storehouse of the fibers (rack) to the pultrusion die. Particular attention was devoted to (a) the guidance system of the fibers and webs, (b) the resin container where the fibers are impregnated, (c) standard plates positioning of the fibers towards the entrance to the spinneret and also (d) reviewed the whole process of assembling and fixing the die as well as its the heating system. With the implementation of these new systems was achieved a significant saving of time set-up and were clearly reduced the unit costs of production. Quality assurance was also increased.

Optimization of antioxidants extraction from coffee silverskin, aroasting by-product, having in view a sustainable process

Coffee silverskin is a major roasting by-product that could be valued as a source of antioxidant compounds. The effect of the major variables (solvent polarity, temperature and extraction time) affecting the extraction yields of bioactive compounds and antioxidant activity of silverskin extracts was evaluated. The extracts composition varied significantly with the extraction conditions used. A factorial experimental design showed that the use of a hydroalcoholic solvent (50%:50%) at 40 °C for 60 min is a sustainable option to maximize the extraction yield of bioactive compounds and the antioxidant capacity of extracts. Using this set of conditions it was possible to obtain extracts containing total phenolics (302.5 ± 7.1 mg GAE/L), tannins (0.43 ± 0.06 mg TAE/L), and flavonoids (83.0 ± 1.4 mg ECE/L), exhibiting DPPHradical dot scavenging activity (326.0 ± 5.7 mg TE/L) and ferric reducing antioxidant power (1791.9 ± 126.3 mg SFE/L). These conditions allowed, in comparison with other “more effective” for some individual parameters, a cost reduction, saving time and energy.

Downstream processing development of enveloped viruses for clinical applications: innovative tools for rational process optimization

Dissertation presented to obtain a Ph.D. degree in Engineering and Technology Sciences, Biotechnology at the Instituto de Tecnologia Química e Biológica, Universidade Nova de Lisboa

Millennium BCP: Optimization of the branches closure process

Nowadays, a significant number of banks in Portugal are facing a bank-branch restructuring problem, and Millennium BCP is not an exception. The closure of branches is a major component of profit maximization through the reduction in operational and personnel costs but also an opportunity to approach the idea of “baking of future” and start thinking on the benefits of the digital era. This dissertation centers on a current high-impact organizational problem addressed by the company and consists in a proposal of optimization to the model that Millennium BCP uses. Even though measures of performance are usually considered the most important elements in evaluating the viability of branches, there is evidence suggesting that other general factors can be important to assess branch potential, such as the influx on branches, business dimensions of a branch and its location, which will be addressed in this project.

Customer service process optimization at Sonae e MC

Sonae MC is constantly innovating and keeping up with the new market trends, being increasingly focused on E-commerce due to its growing importance. In that area, a telephone line is available to support customers with their problems. However, rare were the cases in which those problems were solved in the first contact. Therefore, the goal of this work was to reengineer these processes to improve the service performance and consequently the customer’s satisfaction. Following an evolutionary approach, improvement opportunities were suggested and if correctly implemented the cases resolution time could decrease 1 day and Sonae MC will save €7.750 per month.

Optimization of KOH etching process to obtain textured substrates suitable for heterojunction solar cells fabricated by HWCVD

In this work, we have studied the texturization process of (100) c-Si wafers using a low concentration potassium hydroxide solution in order to obtain good quality textured wafers. The optimization of the etching conditions have led to random but uniform pyramidal structures with good optical properties. Then, symmetric heterojunctions were deposited by Hot-Wire CVD onto these substrates and the Quasi-Steady-State PhotoConductance technique was used to measure passivation quality. Little degradation in the effective lifetime and implicit open circuit voltage of these devices (< 20 mV) was observed in all cases. It is especially remarkable that for big uniform pyramids, the open-circuit voltage is comparable to the values obtained on flat substrates.

The Optimization of Flotation Process Parameters in the Deinking Plant

Tämän diplomityön tavoitteena oli sekundäärisen esiflotaation optimointi Stora Enso Sachsen GmbH:n tehtaalla. Optimoinnin muuttujana käytettiin vaahdon määrää ja optimointiparametreinä ISO-vaaleutta, saantoja sekä tuhkapitoisuutta. Lisäksi tutkittiin flotaatiosakeuden vaikutusta myös muihin tehtaan flotaatioprosesseihin. Kirjallisuusosassa tarkasteltiin flotaatiotapahtumaa, poistettavien partikkeleiden ja ilmakuplien kontaktia, vaahdon muodostumista sekä tärkeimpiä käytössä olevia siistausflotaattoreiden laiteratkaisuja. Kokeellisessa osassa tutkittiin flotaatiosakeuden pienetämisen vaikutuksia tehtaan flotaatioprosesseihin tuhkapitoisuuden, ISO-vaaleuden, valon sironta- ja valon absorpiokerrointen kannalta. Sekundäärisen esiflotaation optimonti suoritettiin muuttamalla vaahdon määrää kolmella erilaisella injektorin koolla, (8 mm, 10 mm ja 13 mm), joista keskimmäinen kasvattaa 30 % massan tilavuusvirtaa ilmapitoisuuden muodossa. Optimonnin tarkoituksena oli kasvattaa hyväksytyn massajakeen ISO-vaaleutta, sekä kasvattaa kuitu- ja kokonaissaantoa sekundäärisessä esiflotaatiossa. Flotaatiosakeuden pienentämisellä oli edullisia vaikutuksia ISO-vaaleuteen ja valon sirontakertoimeen kussakin flotaatiossa. Tuhkapitoisuus pieneni sekundäärisissä flotaatioissa enemmän sakeuden ollessa pienempi, kun taas primäärisissä flotaatiossa vaikutus oli päinvastainen. Valon absorptiokerroin parani jälkiflotaatioissa alhaisemmalla sakeudella, kun taas esiflotaatioissa vaikutus oli päinvastainen. Sekundäärisen esiflotaation optimoinnin tuloksena oli lähes 5 % parempi ISO-vaaleus hyväksytyssä massajakeessa. Kokonaissaanto parani optimoinnin myötä 5 % ja kuitusaanto 2 %. Saantojen nousu tuottaa vuosittaisia säästöjä siistauslaitoksen tuotantokapasiteetin noustessa 0,5 %. Tämän lisäksi sekundäärisessä esiflotaatiossa rejektoituvan massavirran pienentyminen tuottaa lisäsäästöjä tehtaan voimalaitoksella.

Application of simulated annealing in simulation and optimization of drying process of Zea mays malt

Kinetic simulation and drying process optimization of corn malt by Simulated Annealing (SA) for estimation of temperature and time parameters in order to preserve maximum amylase activity in the obtained product are presented here. Germinated corn seeds were dried at 54-76 °C in a convective dryer, with occasional measurement of moisture content and enzymatic activity. The experimental data obtained were submitted to modeling. Simulation and optimization of the drying process were made by using the SA method, a randomized improvement algorithm, analogous to the simulated annealing process. Results showed that seeds were best dried between 3h and 5h. Among the models used in this work, the kinetic model of water diffusion into corn seeds showed the best fitting. Drying temperature and time showed a square influence on the enzymatic activity. Optimization through SA showed the best condition at 54 ºC and between 5.6h and 6.4h of drying. Values of specific activity in the corn malt were found between 5.26±0.06 SKB/mg and 15.69±0,10% of remaining moisture.

Optimization of extrusion process for production of nutritious pellets

A blend of 50% Potato Starch (PS), 35% Quality Protein Maize (QPM), and 15% Soybean Meal (SM) were used in the preparation of expanded pellets utilizing a laboratory extruder with a 1.5 × 20.0 × 100.0 mm die-nozzle. The independent variables analyzed were Barrel Temperature (BT) (75-140 °C) and Feed Moisture (FM) (16-30%). The effect of extrusion variables was investigated in terms of Expansion Index (EI), apparent density (ApD), Penetration Force (PF) and Specific Mechanical Energy (SME), viscosity profiles, DSC, crystallinity by X-ray diffraction, and Scanning Electronic Microscopy (SEM). The PF decreased from 30 to 4 kgf with the increase of both independent variables (BT and FM). SME was affected only by FM, and decreased with the increase in this variable. The optimal region showed that the maximum EI was found for BT in the range of 123-140 °C and 27-31% for FM, respectively. The extruded pellets obtained from the optimal processing region were probably not completely degraded, as shown in the structural characterization. Acceptable expanded pellets could be produced using a blend of PS, QPM, and SM by extrusion cooking.

Spirulina platensis: process optimization to obtain biomass

Spirulina platensis is a photoautotrophic mesophilic cyanobacterium. Its main sources of nutrients are nitrate, urea, and ammonium salts. Spirulina cultivation requires temperature, light intensity, and nutrient content control. This microalgae has been studied and used commercially due to its therapeutic and antioxidant potential. In addition, several studies have reported its ability to use CO2, its immune activity, and use as an adjuvant nutritive factor in the treatment of obesity. The objective of this study is the production of biomass of S. platensis using different rates of stirring, nitrogen source, amount of micronutrients, and luminosity. A 2(4) experimental design with the following factors: stirring (120 and 140 RPM), amount of nitrogen (1.5 and 2.5 g/L), amount of micronutrients (0,25 and 0,75 mL/L) (11 and 15 W), and luminosity was used. Fermentation was performed in a 500 mL conical flask with 250 mL of culture medium and 10% inoculum in an incubator with controlled stirring and luminosity. Fermentation was monitored using a spectrophotometer (560 nm), and each fermentation lasted 15 days. Of the parameters studied, luminosity is the one with the highest significance, followed by the amount of nitrogen and the interaction between stirring and micronutrients. Maximum production of biomass for 15 days was 2.70 g/L under the following conditions: luminosity15W; stirring, 120 RPM; source of nitrogen, 1.5 g/L; and micronutrients, 0.75 mL/L.

Optimization of the extraction process of polyphenols from cashew apple agro-industrial residues

The goal of this study was to determine the chemical composition of cashew apples agro-industrial residue and optimize the process of polyphenols extraction in this residue. The extraction process conditions were defined using a 24-1 fractional factorial experimental design using acetone and methanol as solvents. The independent variables were: time (30 to 90 min), temperature (30 to 50 °C), solvent concentrations (50% to 90%), agitation speed (100 to 300 rpm); the dependent variables were: total phenolic content and DPPH scavenging capacity. The optimized process was carried out by applying the Central Composite Rotational Design (CCRD) considering the results obtained with the 24-1 fractional factorial experimental design. The residue presented bioactive compounds in its composition, with emphasis on the content of total phenolic compounds (1975.64 mg/ 100 g). The extraction process was not affected by methanol; however, acetone affected the amounts of extracted phytochemicals. Extracts with high levels of polyphenols and strong DPPH scavenging capacity (> 80%) were obtained using 55% acetone, 30 minutes, 30 °C, and 150 rpm. The results showed that cashew apple residue is a potential natural source of bioactive compounds with strong antioxidant capacity. These compounds could be used partially or totally to replace synthetic antioxidants.

Optimization of Two Stage Process for the Growth of In2S3 , CuInSe2 and CuIn (Sel-xSx)2Thin Films for Solar Cell Application

Two stage processes consisting of precursor preparation by thermal evaporation followed by chalcogenisation in the required atmosphere is found to be a feasible technique for the PV materials such as n-Beta In2S3, p-CulnSe2, p-CulnS2 and p-CuIn(Sel_xSx)2. The growth parameters such as chalcogenisation temperature and duration of chalcogenisation etc have been optimised in the present study.Single phase Beta-In2S3 thin films can be obtained by sulfurising the indium films above 300°C for 45 minutes. Low sulfurisation temperatures required prolonged annealing after the sulfurisation to obtain single phase Beta-1n2S3, which resulted in high material loss. The maximum band gap of 2.58 eV was obtained for the nearly stoichiometric Beta-In2S3 film which was sulfurised at 350°C. This wider band gap, n type Beta-In2S3 can be used as an alternative to toxic CdS as window layer in photovoltaics .The systematic study on the structural optical and electrical properties of CuInSe2 films by varying the process parameters such as the duration of selenization and the selenization temperature led to the conclusion that for the growth of single-phase CuInSe2, the optimum selenization temperature is 350°C and duration is 3 hours. The presence of some binary phases in films for shorter selenization period and lower selenization temperature may be due to the incomplete reaction and indium loss. Optical band gap energy of 1.05 eV obtained for the films under the optimum condition.In order to obtain a closer match to the solar spectrum it is desirable to increase the band gap of the CulnSe2 by a few meV . Further research works were carried out to produce graded band gap CuIn(Se,S)2 absorber films by incorporation of sulfur into CuInSe2. It was observed that when the CulnSe2 prepared by two stage process were post annealed in sulfur atmosphere, the sulfur may be occupying the interstitial positions or forming a CuInS2 phase along with CuInSe2 phase. The sulfur treatment during the selenization process OfCu11 ln9 precursors resulted in Culn (Se,S)2 thin films. A band gap of 1.38 eV was obtained for the CuIn(Se,S)2.The optimised thin films n-beta 1n2S3, p-CulnSe2 and p-Culn(Sel-xSx)2 can be used for fabrication of polycrystalline solar cells.

Analysis and Optimization of Machining Process Using Evolutionary Algorithms

To ensure quality of machined products at minimum machining costs and maximum machining effectiveness, it is very important to select optimum parameters when metal cutting machine tools are employed. Traditionally, the experience of the operator plays a major role in the selection of optimum metal cutting conditions. However, attaining optimum values each time by even a skilled operator is difficult. The non-linear nature of the machining process has compelled engineers to search for more effective methods to attain optimization. The design objective preceding most engineering design activities is simply to minimize the cost of production or to maximize the production efficiency. The main aim of research work reported here is to build robust optimization algorithms by exploiting ideas that nature has to offer from its backyard and using it to solve real world optimization problems in manufacturing processes.In this thesis, after conducting an exhaustive literature review, several optimization techniques used in various manufacturing processes have been identified. The selection of optimal cutting parameters, like depth of cut, feed and speed is a very important issue for every machining process. Experiments have been designed using Taguchi technique and dry turning of SS420 has been performed on Kirlosker turn master 35 lathe. Analysis using S/N and ANOVA were performed to find the optimum level and percentage of contribution of each parameter. By using S/N analysis the optimum machining parameters from the experimentation is obtained.Optimization algorithms begin with one or more design solutions supplied by the user and then iteratively check new design solutions, relative search spaces in order to achieve the true optimum solution. A mathematical model has been developed using response surface analysis for surface roughness and the model was validated using published results from literature.Methodologies in optimization such as Simulated annealing (SA), Particle Swarm Optimization (PSO), Conventional Genetic Algorithm (CGA) and Improved Genetic Algorithm (IGA) are applied to optimize machining parameters while dry turning of SS420 material. All the above algorithms were tested for their efficiency, robustness and accuracy and observe how they often outperform conventional optimization method applied to difficult real world problems. The SA, PSO, CGA and IGA codes were developed using MATLAB. For each evolutionary algorithmic method, optimum cutting conditions are provided to achieve better surface finish.The computational results using SA clearly demonstrated that the proposed solution procedure is quite capable in solving such complicated problems effectively and efficiently. Particle Swarm Optimization (PSO) is a relatively recent heuristic search method whose mechanics are inspired by the swarming or collaborative behavior of biological populations. From the results it has been observed that PSO provides better results and also more computationally efficient.Based on the results obtained using CGA and IGA for the optimization of machining process, the proposed IGA provides better results than the conventional GA. The improved genetic algorithm incorporating a stochastic crossover technique and an artificial initial population scheme is developed to provide a faster search mechanism. Finally, a comparison among these algorithms were made for the specific example of dry turning of SS 420 material and arriving at optimum machining parameters of feed, cutting speed, depth of cut and tool nose radius for minimum surface roughness as the criterion. To summarize, the research work fills in conspicuous gaps between research prototypes and industry requirements, by simulating evolutionary procedures seen in nature that optimize its own systems.

Optimization of Process Parameters for the Extraction of Gelatin from the Skin of Freshwater Fish and the Evaluation of Physical anal Chemical Characteristics

Faculty of Marine Sciences,Cochin University of Science and Technology

Elaboration and optimization of (Y,Er)Al(3)(BO(3))(4) glassy planar waveguides through the sol-gel process

In this work, a sol-gel route was used to prepare Y(0.9)Er(0.1)Al(3)(BO(3))(4) glassy thin films by spin-coating technique looking for the preparation and optimization of planar waveguides for integrated optics. The films were deposited on silica and silicon substrates using stable sols synthesized by the sol-gel process. Deposits with thicknesses ranging between 520 and 720 nm were prepared by a multi-layer process involving heat treatments at different temperatures from glass transition to the film crystallization and using heating rates of 2 degrees C/min. The structural characterization of the layers was performed by using grazing incidence X-ray diffraction and Raman spectroscopy as a function of the heat treatment. Microstructural evolution in terms of annealing temperatures was followed by high resolution scanning electron microscopy and atomic force microscopy. Optical transmission spectra were used to determine the refractive index and the film thicknesses through the envelope method. The optical and guiding properties of the films were studied by m-line spectroscopy. The best films were monomode with 620 nm thickness and a refractive index around 1.664 at 980 nm wavelength. They showed good waveguiding properties with high light-coupling efficiency and low propagation loss at 632.8 and 1550 nm of about 0.88 dB/cm. (C) 2009 Elsevier B.V. All rights reserved.