Modular manufacturing processes: Status, challenges, and opportunities

Exploration and evaluation of modular concepts for the design of full-scale pharmaceutical manufacturing facilities

The design of biopharmaceutical processes is predominantly driven by the domain of experimental process design. This approach can be further improved by combining multiple domain information such as experiments, unit models, and flowsheet models. Approaches consisting of methods and flowsheet models provide the framework for exploring, analyzing, and ultimately evaluating the combinatorial space of all possible designs within the molecule-to-manufacturing value chain. In recent years, modular process designs are of interest in the pharmaceutical industry because of the shift toward multiproduct, mutiprocess processes. Therefore, a systematic approach for how to evaluate the utilization of the modular plug-n-play concept provides metrics that can propel modular design from a viable design alternative to the selected alternative for full-scale manufacturing. The objective of this paper is to present such an in silico approach for the evaluation of modular designs. The approach is presented as a systematic method and then, is exemplified through the manufacture of an active pharmaceutical ingredient (API). The application of the method shows how to transition from a typical design-for-purpose design alternative to a modular design through the utilization of data, modeling, simulation, and uncertainty/sensitivity analyses for quantification of various selection metrics such as process robustness and flexibility.

Engineered Biocatalytic Synthesis of β-N-Substituted-α-Amino Acids

Non-canonical amino acids (ncAAs) are useful synthons for the development of new medicines, materials, and probes for bioactivity. Recently, enzyme engineering has been leveraged to produce a suite of highly active enzymes for the synthesis of β-substituted amino acids. However, there are few examples of biocatalytic N-substitution reactions to make α,β-diamino acids. In this study, we used directed evolution to engineer the β-subunit of tryptophan synthase, TrpB, for improved activity with diverse amine nucleophiles. Mechanistic analysis shows that high yields are hindered by product re-entry into the catalytic cycle and subsequent decomposition. Additional equivalents of l-serine can inhibit product reentry through kinetic competition, facilitating preparative scale synthesis. We show β-substitution with a dozen aryl amine nucleophiles, including demonstration on a gram scale. These transformations yield an underexplored class of amino acids that can serve as unique building blocks for chemical biology and medicinal chemistry.

Lignocellulosic biorefineries: A multiscale approach for resource exploitation

Biomass can become the source for chemicals towards a sustainable production system. However, the challenges it presents such as the variety of species, their widespread and sparse availability, and the expensive transportation claims for an integrated approach to design the novel production system. Multiscale approaches have not been properly extended to biorefineryes design and deployment, due to the comprehensive experimental and modelling work they require. A systems perspective provides the systematic framework to analyze the availability and composition of raw materials across regions, how that affects process design, the portfolio of products that can be obtained by evaluating the strong link between the biomass features and the process design. The use of lignocellulosic materials requires for a multidisciplinary work, that must lead to new process engineers with technical competences in biology, biotechnology but also process engineering, mathematics, computer science and social sciences towards a sustainable process/chemical industry.

Biomimicry: the nexus for achieving sustainability in the people-process-planet relationship

Population growth inevitably gives rise to an increase in consumption of products and services. This has the domino effect of more exploitation of already scarce natural resources, with its concomitant pollution from the industries that process these natural resources into products and services for man. At the end of life of these products, they are disposed of as waste to landfills. All these issues threaten the sustainable development of any society. To proffer sustainable solutions to the environmental problems associated with the process industry, it has incorporated the concepts of process intensification via modularization, lean manufacturing, and industrial ecology into its operations. These same concepts are used by nature, though in a different way. As nature has survived for billions of years, looking to nature for inspiration - biomimicry, might be the only sustainable solution to the planet's problem. This paper, reviews nature's strategies that have been tested, and are relevant to the process industry. It highlights biomimicry as a powerful tool for achieving sustainability in the people-process-planet relationship as it assists to reduce waste, increase process efficiency and reduce reliance on scarce natural resources. As the process industry seeks to reduce its negative impact on the planet, biomimicry offers a promising approach to creating a more sustainable future.

Dynamic Operability Analysis for Process Design and Control of Modular Natural Gas Utilization Systems

Process modularization is an alternative process design and construction framework, in which modular units are independent and replaceable blocks of a process system. While modular plants have higher efficiency and are safer to construct than conventional stick-built plants (Roy, S. Chem. Eng. Prog. 2017, 113, 28-31), they are significantly more challenging to operate because of the loss in the control degrees of freedom that comes with process integration and intensification (Bishop, B. A.; Lima, F. V. Processes 2021, 9, 2165). To address this challenge, in this work, operability analyses are performed to consider the design and operation of modular units. Initially, a steady-state operability analysis is employed to find a set of feasible modular designs that are able to operate considering different modular plant conditions. A dynamic operability analysis is then applied to the feasible designs to identify the operable designs that are capable of rejecting the operational disturbances. Lastly, a closed-loop control measure is introduced to compare the performances of the different operable designs. The proposed approach is implemented in a modular membrane reactor to find a set of operable designs considering different natural gas wells, and the respective closed-loop nonlinear model predictive control performance of these units is evaluated.

Adoption of modern technologies for implementing industry 4.0: an integrated MCDM approach

Purpose

Modern technologies are seen as an essential component of the fourth industrial revolution (industry 4.0) and their adoption is vital to transform the existing manufacturing system into industry 4.0-based manufacturing system. Therefore, the primary objective of this research explores the barriers of modern technology adoption and their mitigating solutions in order to align with Industry 4.0 objectives.

Design/methodology/approach

Barriers to adopting modern technologies and respective mitigating solutions are identified from the available literature. Further, these barriers are ranked with the help of expert opinions by using the BWM method appropriately. The identified solutions are ranked using the combined compromise solution (CoCoSo) method.

Findings

Several modern technologies and their capabilities are recognised to support the industry 4.0-based manufacturing systems. This study identifies 22 barriers to the effective adoption of modern technologies in manufacturing and 14 solutions to overcome these barriers. Change management, the high initial cost of technology and appropriate support infrastructure are the most significant barriers. The most prominent solutions to overcome the most considerable barriers are ‘supportive research, development and commercialisation environment’, ‘updated policy and effective implementation’ and ‘capacity building through training’ that are the top three solutions that need to be addressed.

Research limitations/implications

The barriers and solutions of modern technology adoption are obtained through a comprehensive literature review, so there is a chance to ignore some significant barriers and their solutions. Furthermore, ranking barriers and solutions is done with expert opinion, which is not free from biases.

Practical implications

This identification and prioritisation of barriers will help managers to understand the barriers so they can better prepare themselves. Furthermore, the suggested solutions to overcome these barriers are helpful for the managers and could be strategically adopted through optimal resource utilisation.

Originality/value

This study proposes a framework to identify and analyse the significant barriers and solutions to adopting modern technologies in the manufacturing system. It might be helpful for manufacturing organisations that are willing to transform their manufacturing system into industry 4.0.

Cooling Crystallization with Complex Temperature Profiles on a Quasi-Continuous and Modular Plant

Volatile markets and increasing demands for quality and fast availability of specialty chemical products have motivated the rise of small-scale, integrated, and modular continuous processing plants. As a significant unit operation used for product isolation and purification, cooling crystallization is part of this trend. Here, the small-scale and integrated quasi-continuous filter belt crystallizer (QCFBC) combines cooling crystallization, solid-liquid separation, and drying on a single apparatus. This contribution shows the general working principle, different operation modes, and possibilities of temperature control with the modular setup. For precise temperature control in cooling crystallization, Peltier elements show promising results in a systematic study of different operation parameters. Sucrose/water was used as a model substance system. The results confirm that seed crystal properties are the most important parameter in crystallization processes. Additionally, an oscillating temperature profile has a narrowing effect on the crystal size distribution (CSD). The integrated, small-scale, and modular setup of the QCFBC offers high degrees of flexibility, process control, and adaptability to cope with future market demands.

Managing the Tension between Trust and Confidentiality in Mobile Supply Chains

This research investigates the tension between trust and confidentiality in Mobile Supply Chains (MSCs), where a production asset that is owned by one of the partners is outsourced to another partner of the supply chain for the production of goods, chemicals, or pharmaceuticals. The novelty of the MSC concept is to be found in its innovative and sustainable approach to production and operation processes in supply chains. Implementation of the MSC model could, however, raise trust and confidentiality concerns. The interplay of trust and confidentiality, or preservation of information privacy, between partners plays a central role in the supply chains, particularly because they are genuinely dependent on each other. Qualitative data analysis was used, in which semi-structured interviews with the experts from the chemical and pharmaceutical industries in Germany were conducted to investigate the tension between trust and confidentiality, and important factors affecting it. The results of the study present four different integration scenarios, namely, the low-quality, conservative, grey-box, and innovation scenarios, which consider different levels of trust, confidentiality and information sharing. Subsequently, the tension between trust and confidentiality is analyzed within these scenarios, and three effective strategies which encourage partners to balance the tension between trust and confidentiality are proposed. The study indicates that the balance between trust and confidentiality can be maintained in some scenarios when critical factors such as transparency, trust negotiation, and a reward-sharing system are present.

Sustainable Coproduction of Two Disinfectants via Hydroxide-Balanced Modular Electrochemical Synthesis Using a Redox Reservoir

Challenges posed by the sacrificial auxiliary reactions and expensive ion-exchange membranes in conventional electrosynthesis necessitate developing new electrochemical processes to enable efficient and sustainable distributed electrochemical manufacturing. Modular electrochemical synthesis (ModES) using a redox reservoir (RR) offers a promising membrane-free approach to improve energy efficiency and reduce waste through the pairing of multiple independent oxidative and reductive half-reactions; however, undesired ion-imbalance and induced pH changes in the existing ModES process limit sustained production. Here we present Ni(OH)₂ as a heterogeneous RR that can selectively store and transport the hydroxide ions involved in the target half-reactions by reversible conversion with NiOOH to enable an ion-balanced ModES of two common disinfectants, hydrogen peroxide (H₂O₂) and sodium hypochlorite (NaClO). This hydroxide-balanced ModES realizes stable operation without appreciable pH swing to accumulate practically useful concentrations of H₂O₂ and NaClO up to 251 and 481 ppm, respectively. These results illustrate additional design principles for electrosynthesis without sacrificial auxiliary reactions and the need for ion-selective RRs for modular electrochemical manufacturing.

Development and Commissioning of a Small-Scale, Modular and Integrated Plant for the Quasi-Continuous Production of Crystalline Particles

Increasing global competition, volatile markets and the demand for individual products challenge companies in almost all business sectors and require innovative solutions. In the chemical and pharmaceutical industries, these include modular design, the integration of several unit operations in one apparatus and the development of small-scale, versatile multipurpose plants. An example for such a modular, integrated and small-scale system is the belt crystallizer. This device combines the process steps cooling crystallization, solid-liquid separation and contact drying in a single plant. The basis of the apparatus is a belt filter in which the vacuum trays below the filter medium are replaced by temperature control and filtration units. Due to identical dimensions, it is possible to arrange the individual functional units in any order, which in turn allows a high degree of flexibility and rapid adaptation to customer requirements. Within the scope of the publication, the commissioning of the belt crystallizer takes place. First of all, the general functionality of the plant concept is demonstrated using sucrose as model system. Further experiments show that the particle size and the distribution width of the manufactured crystals can be specifically influenced by the selected process parameters, e.g., temperature profile during cooling and residence time.

Novel Module-Based Membrane Reactor Design Approach for Improved Operability Performance

This work aims to address the design and control challenges caused by the integration of phenomena and the loss of degrees of freedom (DOF) that occur in the intensification of membrane reactor units. First, a novel approach to designing membrane reactor units is proposed. This approach consists of designing smaller modules based on specific phenomena such as heat exchange, reactions, and mass transport and combining them in series to produce the final modular membrane-based unit. This approach to designing membrane reactors is then assessed using a process operability analysis for the first time to maximize the operability index, as a way of quantifying the operational performance of intensified processes. This work demonstrates that by designing membrane reactors in this way, the operability of the original membrane reactor design can be significantly improved, translating to an improvement in achievability for a potential control structure implementation.

Status and prospects of the decentralised valorisation of natural gas into energy and energy carriers

We critically review the recent advances in process, reactor, and catalyst design that enable process miniaturisation for decentralised natural gas upgrading into electricity, liquefied natural gas, fuels and chemicals.

Room temperature and atmospheric pressure aqueous partial oxidation of ethane to oxygenates over AuPd catalysts

The aqueous partial oxidation of ethane over unsupported AuPd catalysts is investigated at 21 °C and 1 bar ethane.

Modular design: Implementing proven engineering principles in biotechnology

Modular design is at the foundation of contemporary engineering, enabling rapid, efficient, and reproducible construction and maintenance of complex systems across applications. Remarkably, modularity has recently been discovered as a governing principle in natural biological systems from genes to proteins to complex networks within a cell and organism communities. The convergent knowledge of natural and engineered modular systems provides a key to drive modern biotechnology to address emergent challenges associated with health, food, energy, and the environment. Here, we first present the theory and application of modular design in traditional engineering fields. We then discuss the significance and impact of modular architectures on systems biology and biotechnology. Next, we focus on the very recent theoretical and experimental advances in modular cell engineering that seeks to enable rapid and systematic development of microbial catalysts capable of efficiently synthesizing a large space of useful chemicals. We conclude with an outlook towards theoretical and practical opportunities for a more systematic and effective application of modular cell engineering in biotechnology.

Smart Cyber-Physical Manufacturing: Extended and Real-Time Optimization of Logistics Resources in Matrix Production

In the context of Industry 4.0, the matrix production concept represents revolutionary solutions from a technological and logistics point of view. In a matrix production system, flexible, configurable production and assembly cells are arranged in a grid layout, and the in-plant supply is based on autonomous vehicles. Adaptable and flexible material handling solutions are required to perform the dynamically changing supply-demands of standardized and categorized manufacturing and assembly cells. Within the frame of this paper, the authors describe the in-plant supply process of matrix production and the optimization potential in these processes. After a systematic literature review, this paper introduces the structure of matrix production as a cyber-physical system focusing on logistics aspects. A mathematical model of this in-plant supply process is described including extended and real-time optimization from routing, assignment, and scheduling points of view. The optimization problem described in the model is an NP-hard problem. There are no known efficient analytical methods to find the best solution for this kind of problem; therefore, we use heuristics to find a suitable solution for the above-described problem. Next, a sequential black hole–floral pollination heuristic algorithm is described. The scenario analysis, which focuses on the clustering and routing aspects of supply demands in a matrix production system, validates the model and evaluates its performance to increase cost-efficiency and warrants environmental awareness of the in-plant supply in matrix production.