Advanced production scheduling for batch plants in process industries

An Advanced Planning System (APS) offers support at all planning levels along the supply chain while observing limited resources. We consider an APS for process industries (e.g. chemical and pharmaceutical industries) consisting of the modules network design (for long–term decisions), supply network planning (for medium–term decisions), and detailed production scheduling (for short–term decisions). For each module, we outline the decision problem, discuss the specifi cs of process industries, and review state–of–the–art solution approaches. For the module detailed production scheduling, a new solution approach is proposed in the case of batch production, which can solve much larger practical problems than the methods known thus far. The new approach decomposes detailed production scheduling for batch production into batching and batch scheduling. The batching problem converts the primary requirements for products into individual batches, where the work load is to be minimized. We formulate the batching problem as a nonlinear mixed–integer program and transform it into a linear mixed–binary program of moderate size, which can be solved by standard software. The batch scheduling problem allocates the batches to scarce resources such as processing units, workers, and intermediate storage facilities, where some regular objective function like the makespan is to be minimized. The batch scheduling problem is modelled as a resource–constrained project scheduling problem, which can be solved by an efficient truncated branch–and–bound algorithm developed recently. The performance of the new solution procedures for batching and batch scheduling is demonstrated by solving several instances of a case study from process industries.

Label-free SERS for natural product provenance

Introduction Natural product provenance is important in the food, beverage and pharmaceutical industries, for consumer confidence and with health implications. Raman spectroscopy has powerful molecular fingerprint abilities. Surface Enhanced Raman Spectroscopy’s (SERS) sharp peaks allow distinction between minimally different molecules, so it should be suitable for this purpose. Methods Naturally caffeinated beverages with Guarana extract, coffee and Red Bull energy drink as a synthetic caffeinated beverage for comparison (20 µL ea.) were reacted 1:1 with Gold nanoparticles functionalised with anti-caffeine antibody (ab15221) (10 minutes), air dried and analysed in a micro-Raman instrument. The spectral data was processed using Principle Component Analysis (PCA). Results The PCA showed Guarana sourced caffeine varied significantly from synthetic caffeine (Red Bull) on component 1 (containing 76.4% of the variance in the data). See figure 1. The coffee containing beverages, and in particular Robert Timms (instant coffee) were very similar on component 1, but the barista espresso showed minor variance on component 1. Both coffee sourced caffeine samples varied with red Bull on component 2, (20% of variance). ************************************************************ Figure 1 PCA comparing a naturally caffeinated beverage containing Guarana with coffee. ************************************************************ Discussion PCA is an unsupervised multivariate statistical method that determines patterns within data. Figure 1 shows Caffeine in Guarana is notably different to synthetic caffeine. Other researchers have revealed that caffeine in Guarana plants is complexed with tannins. Naturally sourced/ lightly processed caffeine (Monster Energy, Espresso) are more inherently different than synthetic (Red Bull) /highly processed (Robert Timms) caffeine, in figure 1, which is consistent with this finding and demonstrates this technique’s applicability. Guarana provenance is important because it is still largely hand produced and its demand is escalating with recognition of its benefits. This could be a powerful technique for Guarana provenance, and may extend to other industries where provenance / authentication are required, e.g. the wine or natural pharmaceuticals industries.

Bioprocess engineering of microalgae to produce a variety of consumer products

Microalgae biotechnology has recently emerged into the lime light owing to numerous consumer products that can be harnessed from microalgae. Product portfolio stretches from straightforward biomass production for food and animal feed to valuable products extracted from microalgal biomass, including triglycerides which can be converted into biodiesel. For most of these applications, the production process is moderately economically viable and the market is developing. Considering the enormous biodiversity of microalgae and recent developments in genetic and metabolic engineering, this group of organisms represents one of the most promising sources for new products and applications. With the development of detailed culture and screening techniques, microalgal biotechnology can meet the high demands of food, energy and pharmaceutical industries. This review article discusses the technology and production platforms for development and creation of different valuable consumer products from microalgal biomass.

Polymerization of Ethene and Branched α-olefins with Group IV Metal Complexes Bearing Nitrogen- and Oxygen-Based Ligands

The commodity plastics that are used in our everyday lives are based on polyolefin resins and they find wide variety of applications in several areas. Most of the production is carried out in catalyzed low pressure processes. As a consequence polymerization of ethene and α-olefins has been one of the focus areas for catalyst research both in industry and academia. Enormous amount of effort have been dedicated to fine tune the processes and to obtain better control of the polymerization and to produce tailored polymer structures The literature review of the thesis concentrates on the use of Group IV metal complexes as catalysts for polymerization of ethene and branched α-olefins. More precisely the review is focused on the use of complexes bearing [O,O] and [O,N] type ligands which have gained considerable interest. Effects of the ligand framework as well as mechanical and fluxional behaviour of the complexes are discussed. The experimental part consists mainly of development of new Group IV metal complexes bearing [O,O] and [O,N] ligands and their use as catalysts precursors in ethene polymerization. Part of the experimental work deals with usage of high-throughput techniques in tailoring properties of new polymer materials which are synthesized using Group IV complexes as catalysts. It is known that the by changing the steric and electronic properties of the ligand framework it is possible to fine tune the catalyst and to gain control over the polymerization reaction. This is why in this thesis the complex structures were designed so that the ligand frameworks could be fairly easily modified. All together 14 complexes were synthesised and used as catalysts in ethene polymerizations. It was found that the ligand framework did have an impact within the studied catalyst families. The activities of the catalysts were affected by the changes in complex structure and also effects on the produced polymers were observed: molecular weights and molecular weight distributions were depended on the used catalyst structure. Some catalysts also produced bi- or multi-modal polymers. During last decade high-throughput techniques developed in pharmaceutical industries have been adopted into polyolefin research in order to speed-up and optimize the catalyst candidates. These methods can now be regarded as established method suitable for both academia and industry alike. These high-throughput techniques were used in tailoring poly(4-methyl-1-pentene) polymers which were synthesized using Group IV metal complexes as catalysts. This work done in this thesis represents the first successful example where the high-throughput synthesis techniques are combined with high-throughput mechanical testing techniques to speed-up the discovery process for new polymer materials.

Functional interaction of diphenols with polyphenol oxidase - Molecular determinants of substrate/inhibitor specificity SO FEBS JOURNAL

Polyphenol oxidase (PPO) catalyzes the oxidation of o-diphenols to their respective quinones. The quinones autopolymerize to form dark pigments, an undesired effect. PPO is therefore the target for the development of antibrowning and antimelanization agents. A series of phenolic compounds experimentally evaluated for their binding affinity and inhibition constants were computationally docked to the active site of catechol oxidase. Docking studies suggested two distinct modes of binding, dividing the docked ligands into two groups. Remarkably, the first group corresponds to ligands determined to be substrates and the second group corresponds to reversible inhibitors. Analyses of the complexes provide structural explanations for correlating subtle changes in the position and nature of the substitutions on o-diphenols to their functional properties as substrates and inhibitors. Higher reaction rates and binding are reckoned by additional interactions of the substrates with key residues that line the hydrophobic cavity. The docking results suggest that inhibition of oxidation stems from an interaction between the aromatic carboxylic acid group and the apical His 109 of the four coordinates of the trigonal pyramidal coordination polyhedron of CuA. The spatial orientation of the hydroxyl in relation to the carboxylic group either allows a perfect fit in the substrate cavity, leading to inhibition, or because of a steric clash flips the molecule vertically, facilitating oxidation. This is the first study to explain, at the molecular level, the determinants Of substrate and inhibitor specificity of a catechol oxidase, thereby providing a platform for the design of selective inhibitors useful to both the food and pharmaceutical industries.

Purifying water containing both anionic and cationic species using a (Zn, Cu)O, ZnO, and Cobalt Ferrite based multiphase adsorbent system

For the purpose of water purification, novel and low-cost adsorbents which are promising replacements for activated carbon are being actively pursued. However, a single-phase material that adsorbs both cationic and anionic species remains elusive. Hence, a low-cost, multiphase adsorbent bed that purifies water containing both anionic and cationic pollutants is a desirable alternative. We choose anionic (Congo red, Orange G) and cationic (methylene blue, malachite green) dyes as model pollutants. These dyes are chosen since they are widely found in effluents from textile, leather, fishery, and pharmaceutical industries, and their carcinogenic, mutagenic, genotoxic, and cytotoxic impact on mammalian cells is well-established. We show that ZnO, (Zn0.24Cu0.76)O and cobalt ferrite based multiphase fixed adsorbent bed efficiently adsorbs model anionic (Congo red, Orange G) and cationic (methylene blue and malachite green) pollutants, and their complex mixtures. All adsorbent phases are synthesized using room-temperature, high-yield (similar to 96-100%), green chemical processes. The nanoadsorbents are characterized by using X-ray powder diffraction (XRD), scanning electron microscopy (SEM), Brunauer-Emmett-Teller (BET) surface area analysis, and zeta potential measurements. The constituent nanophases are deliberately chosen to be beyond 50 nm, in order to avoid the nanotoxic size regime of oxides. Adsorption characteristics of each of the phases are examined. Isotherm based analysis shows that adsorption is both spontaneous and highly favorable. zeta potential measurements indicate that electrostatic interactions are the primary driving force for the observed adsorption behavior. The isotherms obtained are best described using a composite Langmuir-Freundlich model. Pseudo-first-order, rapid kinetics is observed (with adsorption rate constants as high as 0.1-0.2 min(-1) in some cases). Film diffusion is shown to be the primary mechanism of adsorption.

A assistência farmacêutica no Brasil contemporâneo: a produção pública de medicamento permite ampliar o acesso da população ao uso racional de medicamentos?

O presente estudo avalia a produção pública de medicamentos no Brasil, abordando as possibilidades de avanços no acesso aos medicamentos essenciais. Fundamentou-se na análise bibliográfica e documental. Esta última análise focou os documentos oficiais, originários dos diversos agentes institucionais vinculados à política de medicamentos do país. A Política Nacional de Medicamentos concentrou-se na provisão da assistência farmacêutica e, em especial, no acesso racional aos medicamentos essenciais. A pesquisa, de caráter histórico, destacou analiticamente o desenvolvimento dessa política desde 2003 até o presente. Nesse contexto, privilegiam-se as características universais do atual sistema de saúde no Brasil e o compromisso do Estado nacional em garantir o acesso a esse direito fundamental. Foram também objeto de destaque nesta pesquisa as alternativas de oferta de medicamentos por intermédio da indústria farmacêutica internacional e nacional. O núcleo deste estudo é a análise da produção dos medicamentos pelos laboratórios oficiais, bem como das dificuldades que esses laboratórios enfrentam em função da descontinuidade histórica de políticas voltadas para o fortalecimento de suas atividades. Assim, permite-se afirmar que a produção dos medicamentos essenciais poderia contribuir de forma decisiva para a inclusão da população historicamente excluída das políticas de saúde a partir de estratégias para o seu fortalecimento continuado, definidas pelo Estado brasileiro.

Estratégia para validação de processos de esterilização por vapor saturado em autoclaves nas indústrias farmacêuticas

O objetivo deste trabalho foi criar uma metodologia de validação e revalidação dos processos de esterilização por calor úmido em autoclaves horizontais, destacando os pontos críticos do processo e concentrando esforços onde são realmente necessários. Foram realizados estudos de distribuição térmica, de penetração de calor e de desafio microbiológico na validação da autoclave STERIS FINNAQUA 6912. Com o objetivo de avaliar o impacto de uma mudança e compreender a relação entre os fatores e suas interações para o processo de esterilização, foi utilizado o planejamento fatorial 23 dos fatores densidade da carga (quantidade de itens), embalagem do produto e localização na câmara interna. Os estudos de distribuição térmica confirmaram a distribuição homogênea de calor na câmara interna durante o tempo de exposição a 121C. As temperaturas variaram entre 120,35C e 120,92C com desvio padrão máximo de 0,12C. Os estudos de penetração de calor confirmaram exposições equivalentes a 121C por 24 minutos em todos os itens da carga (F0 > 24 minutos). Em todos os estudos para cargas secas, os índices de capacidade do processo (Cpk) foram maiores que 1,33. Os ensaios de desafio microbiológico garantiram níveis de esterilidade (S.A.L.) maiores que 12 reduções logarítmicas em relação aos indicadores biológicos Geobacillus stearothermophilus. Não foi detectada a presença de endosporos sobreviventes nos 132 indicadores biológicos utilizados nos quatro ciclos desafiados. Com base no planejamento experimental verificou-se que, para o nível de significância de 95% , as mudanças nos fatores posição, embalagem e quantidade da carga não são significativas para o processo de esterilização, em autoclave com remoção forçada de ar. Já para o nível de significância de 90%, a interação Posição x Embalagem apresentou significância estatística no processo de esterilização com valor P de 0,080

A relação entre indústria farmacêutica e a assistência farmacêutica no âmbito do Sistema Único de Saúde (SUS): a compra estadual e municipal de medicamentos no Rio de Janeiro

Esta dissertação tem como objeto o estudo da relação estabelecida entre a indústria farmacêutica e a assistência farmacêutica no âmbito do SUS. O objetivo é avaliar como estão sendo feitas as compras de medicamentos para os programas de assistência farmacêutica básica para hipertensão, diabetes e asma e rinite. A captura de dados foi realizada nas Secretarias de Saúde do estado e do município do Rio de Janeiro. Realizou-se comparação dos preços unitários dos medicamentos adquiridos no estado, no município do Rio de Janeiro e no Banco de Preços em Saúde (BPS), no período de janeiro de 2000 a dezembro de 2006. Em alguns momentos foram utilizados dados da Revista ABCFARMA, sobre preços unitários do mercado varejista. A pesquisa tornou possível registrar que o Estado do Rio de Janeiro compra medicamentos a um preço unitário mais alto do que aqueles praticados pela prefeitura e pelo Banco de Preços em Saúde. A hipótese apresentada é que o preço unitário mais alto se deve às inúmeras compras emergenciais realizadas, que estimulam os fornecedores a compensar o risco com preços maiores. Como a maioria dos fornecedores é distribuidora de medicamentos, elas estariam onerando os preços unitários, pois tiveram problemas no passado com o cumprimento da dívida pelo estado. Segundo autoridades estaduais da Secretaria de Estado de Saúde, esta situação indesejável está sendo superada através de uma nova forma de aquisição de medicamentos. A prefeitura do Rio de Janeiro, por outro lado, tem realizado as compras de medicamentos por licitações na modalidade concorrência. Esta forma possibilitou a aquisição de medicamentos a preços inferiores aos outros entes pesquisados. A maioria dos fornecedores da prefeitura é a própria indústria de medicamentos, o que, em princípio, torna o preço mais baixo. Conclui-se, então: que o Estado do Rio de Janeiro passou por crises de desabastecimento ou abastecimento irregular dos programa de assistência farmacêutica básica, o que contribuiu para a elevação dos preços praticados; e que a prefeitura do Rio de Janeiro tem conseguido comprar medicamentos em condições mais favoráveis que o governo de estado.

Estudo para minimização do processo de fumigação empregado na limpeza e desinfecção de salas limpas em Bio-Manguinhos/ FIOCRUZ

As indústrias farmacêuticas que utilizam salas limpas, em seus processos produtivos, devem controlar ao máximo o nível de contaminantes microbiológicos, baseada na legislação RDC 210 que determina o cumprimento das diretrizes estabelecidas no Regulamento Técnico das Boas Práticas para a Fabricação de Medicamentos. Diante deste cenário, a proposta deste trabalho é avaliar o processo de fumigação com o reagente formaldeído, para a limpeza e desinfecção de salas limpas do Instituto de Tecnologia de Imunobiológicos Bio-Manguinhos. Então, foram desenvolvidas as seguintes etapas: diagnóstico com as indústrias farmacêuticas para traçar um perfil quanto ao uso da fumigação; quantificação de resíduos gerados; avaliação da exposição dos operadores ao formaldeído que é cancerígeno e acompanhamento dos resultados do monitoramento ambiental do ar e de superfícies, inicialmente na sala limpa do SEFBC, cuja atividade principal é a formulação de vacinas bacterianas e biofármacos, após a implantação do espaçamento da fumigação. Os resultados discutidos na presente dissertação mostraram, que a maior parte das indústrias farmacêuticas, não realiza a desinfecção por intermédio da fumigação e que o resíduo gerado neste processo é o mais crítico. E, sobretudo, o monitoramento microbiológico do ar e de superfícies da sala limpa do SEFBC, a partir da metodologia adotada de espaçamento da fumigação, comprovou que não é necessário o emprego deste processo de forma rotineira, para garantir os níveis exigidos de limpeza e desinfecção da respectiva área

Avaliação de toxicidade de efluentes industriais utilizando organismos de três níveis tróficos.

O objetivo do estudo foi avaliar a qualidade de efluentes líquidos industriais, pela caracterização físico-química e ensaios ecotoxicológicos agudos com Danio rerio, Daphnia similis e Vibrio fischeri. Foram comparadas as sensibilidades dos organismos-teste aos variados tipos de efluentes (indústrias alimentícias, papeleiras, bebidas, petroquímicas e farmacêutica), sendo que estes organismos pertencem a três níveis tróficos diferentes. Além disso, foi implementado o método de ensaio com bactérias luminescentes, o Microtox, de acordo com a NBR 15411 (ABNT, 2006). Na maioria dos ensaios, os efluentes apresentaram parâmetros físico-químicos dentro dos limites permitidos pela legislação. Mesmo assim, algumas vezes foram observados efeitos nos organismos-teste. Foram utilizados efluentes tratados das ETEI, podendo ser avaliada a sensibilidade de cada organismo a cada efluente do estudo. Para a Indústria Alimentícia 1 foram realizadas coletas de efluente bruto e primário, que se mostraram tóxicos aos três organismos. Essa coleta também foi realizada para a Indústria Farmacêutica, na qual o efluente bruto foi tóxico aos três organismos e o efluente do tratamento primário, foi tóxico à Daphnia similis e à Vibrio fischeri. O efluente bruto da Indústria Alimentícia 2, da Indústria de Papel e Celulose 2 e da Indústria de Bebidas foram coletados e avaliados ecotoxicologicamente por meio do ensaio Microtox, demonstrando toxicidade aguda com baixos valores de CE(I)50 para todas as indústrias. Alguns parâmetros físicoquímicos das indústrias foram correlacionados com a toxicidade do efluente final para Daphnia similis, Danio rerio e Vibrio fischeri por meio da correlação de Spearman. O teste não paramétrico Mann-Whitney foi usado para comparar grupos de parâmetros físico-químicos que apresentaram presença ou ausência de toxicidade. Em alguns efluentes tratados das ETEI das Indústrias Alimentícia 1, Alimentícia 2, de Papel e Celulose 2 e Petroquímica 1, foram observadas respostas biológicas das bactérias aos efluentes, o efeito hormesis, que indica que a amostra não possui toxicidade aguda, mas é muito provável que apresente toxicidade crônica.

Biosynthesis of fluorescent allophycocyanin alpha-subunits by autocatalysis in Escherichia coli

APC (allophycocyanin) is widely used for fluorescence tagging and may be a promising antioxidant agent for use within the food and pharmaceutical industries. Chromophore attachment to apo-ApcA (apo-APC alpha-subunit without chromophore) can be auto-catalysed both in vitro and in vivo. In the present study, a plasmid containing genes of apo-ApcA and chromophore synthetases (HOI (ferredoxin-dependent haem oxygenase) and PcyA (phycocyanobilin:ferredoxin oxidoreductase)] was constructed and expressed in Escherichia coli. The results show that holo-ApcA (APC alpha-subunit with chromophore) can be synthesized by autocatalysis in E. coli. Recombinant holo-ApcA showed the same spectral and fluorescent properties as PC (phycocyanin) and could serve as a good substitute for native PC for fluorescent tagging. Moreover, recombinant ApcA can inhibit hydroxyl and peroxyl radicals more strongly than holo-ApcA and native APC. The EC50 values were 296.4 +/- 22.4 mu g/ml against hydroxyl radicals and 38.5 +/- 2.6 mu g/ml against peroxyl radicals.

In vitro determination of antioxidant activity of proteins from jellyfish Rhopilema esculentum

In this study, the antioxidant activity of proteins isolated from jellyfish, Rhopilema esculentum Kishinouye (R. esculentum), was determined by various antioxidant assays, including superoxide anion radical-scavenging, hydroxyl radical-scavenging, total antioxidant activity, reducing power and metal chelating activity. Butylated hydroxyanisole (BHA), butylated hydroxytoluene (BHT), alpha-tocopherol, vitamin C and mannitol were used as standards in those various antioxidant activities. The crude protein (CP) and the protein fractions isolated by Sephadex chromatography, first peak (FP) and second peak (SP), had very low reductive power and metal chelating abilities compared to EDTA, but they showed strong scavenging effects on the superoxide anion radical, hydroxyl radical and varying total antioxidant activity. FP and SP exhibited stronger scavenging effects on the superoxide anion radical than BHA, BHT or a-tocopherol. The EC50 values of FP and SP were 6.12 and 0.88 mu g/ml, respectively, while values EC50 of BHA, BHT and alpha-tocopherol were 31, 61 and 88 mu g/ml, respectively. CP, FP and SP showed far higher hydroxyl radical-scavenging activities than did vitamin C or mannitol. The EC50 values of CP, FP and SP were 48.76, 45.42 and 1.52 mu g/ml, but EC50 values of vitamin C and mannitol were 1907 and 4536 mu g/ml, respectively. In a beta-carotene-linoleate system, SP and CP showed antioxidant activity, but lower than BHA. Of the three samples, SP had the strongest antioxidant activity. So, SP may have a use as a possible supplement in the food and pharmaceutical industries. (c) 2005 Elsevier Ltd. All rights reserved.

Radical scavenging activity of protein from tentacles of jellyfish Rhopilema esculentum

In this study, radical scavenging activity of protein from tentacles of jellyfish Rhopilema esculentum (R. esculentum) was assayed including superoxide anion radical and hydroxyl radical scavenging. The protein samples showed strong scavenging activity on superoxide anion radical and values EC50 of full protein (FP), first fraction (IFF), second fraction (SF), and 30% (NH4)(2)SO4 precipitate (Fr-1) were 2.65, 7.28, 1.10, and 22.51 mu g/mL, respectively, while values EC50 of BHA, BHT, and alpha-tocopherol were 31, 6 1, and 88 pg/mL, respectively. Also, the protein samples had strong scavenging effect on hydroxyl radical and the values EC50 of FP, FF, SF, Fr-1, and Fr-2 were 48.91, 27.72, 1.82, 16.36, and 160.93 mu g/mL, but values EC50 of Vc and mannitol were 1907 and 4536 mu g/mL, respectively. Of the five protein samples, SF had the strongest radical scavenging activity and may have a use as a possible supplement in the food and pharmaceutical industries. The radical scavenging activity was stable at high temperature so that R. esculentum may be used as a kind of natural functional food. (c) 2005 Elsevier Ltd. All rights reserved.

Use of MIR Spectroscopy for Optimisation of Biogas Plants

MIR spectroscopy is an established technique which has process monitoring applications in the chemical and pharmaceutical industries. Previous attempts to utilise the technology for monitoring of AD plants were of limited success, with operation hindered by severe clogging of the probe.

Novel fittings, which allow a probe to be withdrawn from the process fluid, cleaned and recalibrated in situ have now been developed to combat this clogging problem. This has allowed a spectroscopic probe to be used successfully in lab scale digesters for real time measurement of VFA concentration, a key parameter to the stability of AD plants.

This project will demonstrate the technology at a farm scale AD plant for the first time. Both real-time measurements of VFA concentrations and parameters currently measured by plant operators will be available, leading to state-of-the-art monitoring and control of the AD plant. With the improved monitoring that this probe will deliver, it is hoped to realise a 10% increase in biogas production without compromising the stability of the process. This will deliver both economic and environmental benefits.