Improving the process quality using statistical design of experiments: a case study

Boost dynamic protocols for producing mammalian biopharmaceuticals with intensified DoE—a practical guide to analyses with OLS and hybrid modeling

Introduction: For the implementation of robust bioprocesses, understanding of temporal cell behavior with respect to relevant inputs is crucial. Intensified Design of Experiments (iDoE) is an efficient tool to assess the joint influence of input parameters by including intra-experimental changes.

Methods: We applied iDoE to the production phase of a monoclonal antibody in a mammalian bioprocess. The multidimensional design space spanned by temperature, dissolved oxygen (DO), timing of change, and growth category was investigated in 12 cultivations. We built ordinary least squares (OLS) and hybrid models (HM) on the iDoE-data, validated them with classical DoE (cDoE)-derived data, and used the models as in silico representation for process optimization.

Results: If the complexity of interactions between changing setpoints of inputs is sufficiently captured during planning and modeling, iDoE proved to be valid for characterizing the mammalian biopharmaceutical production phase. For local behavior and flexible composition of optimization goals, OLS regressions can easily be implemented. To predict global and interconnected dynamics while incorporating mass balances, HM holds potential.

Discussion: iDoE will boost protocols that optimize inputs for different bioprocess phases. The described key aspects of OLS- and HM-based analyses of iDoE-data shall guide future applications during manufacturing.

Green Tea Waste as an Efficient Adsorbent for Methylene Blue: Structuring of a Novel Adsorbent Using Full Factorial Design

Adsorptive removal of methylene blue (MB) from contaminated water samples was achieved using green tea waste (GTW). Adsorption of MB onto raw (RGTW) and thermally treated waste (TTGTW250–TTGTW500) was explored. The performance of the tested adsorbents was assessed in terms of percentage removal of MB (%R) and adsorption capacity (qe, mg/g). A full factorial design (FFD) was employed to optimize the adsorption of MB onto both RGTW and TTGTW500. Four factors were studied: pH, adsorbent dose (AD), dye concentration (DC), and contact time (CT). Value for %R of 96.58% and 98.07% were obtained using RGTW and TTGTW500, respectively. FT-IR and Raman analyses were used to study the surfaces of the prepared adsorbents, and the IR spectrum showed the existence of a variety of functionalities on the surfaces of both the RGTW and thermally treated samples. BET analysis showed the presence of mesopores and macropores in the case of RGTW and micropores in the case of thermally processed adsorbents. Equilibrium studies indicated that the Freundlich isotherm best described the adsorption of MB onto both adsorbents. The maximum adsorption capacity (q_max) was found to be 68.28 and 69.01 mg/g for RGTW and TTGTW500, respectively, implying the superior capacity of TTGTW500 in removing MB. Adsorption of MB was found to proceed via chemisorption (RGTW) and physisorption (TTGTW500), as indicated by the Dubinin–Radushkevich (D-R) isotherm. A pseudo-second order (PSO) model best demonstrated the kinetics of the MB adsorption onto both adsorbents.

Analysis of diclofenac in water samples using in situ derivatization-vortex-assisted liquid-liquid microextraction with gas chromatography-mass spectrometry

A novel micro-extraction technique for a rapid and sensitive analysis of diclofenac (DCF) in water samples has been developed. DCF was derivatized and extracted simultaneously using vortex-assisted liquid-liquid micro-extraction (VALLME) prior to gas chromatography with mass spectrometry detection. The effects of extraction solvent volume, extraction and derivatization time and ionic strength of the sample were studied using 23 factorial experimental design. The optimum extraction conditions were as follows: 200 μL of chloroform, 25 μL of N-methyl-N-trimethylsilyl-trifluoroacetamide (MSTFA) derivatization reagent, vortex extraction and derivatization time 5 min at 3000 rpm. The extraction recovery for different fortification levels was 98 %. Also, the proposed micro-extraction method exhibited results comparable with the solid phase extraction of real water samples. The proposed one-step VALLME and derivatization method is simpler and faster than the conventional extraction and derivatization methods used for the determination of DCF in real water samples.

Effect and interaction study of acetamiprid photodegradation using experimental design

The methodology of experimental research was carried out using the MODDE 6.0 software to study the acetamiprid photodegradation depending on the operating parameters, such as the initial concentration of acetamiprid, concentration and type of the used catalyst and the initial pH of the medium. The results showed the importance of the pollutant concentration effect on the acetamiprid degradation rate. On the other hand, the amount and type of the used catalyst have a considerable influence on the elimination kinetics of this pollutant. The degradation of acetamiprid as an environmental pesticide pollutant via UV irradiation in the presence of titanium dioxide was assessed and optimized using response surface methodology with a D-optimal design. The acetamiprid degradation ratio was found to be sensitive to the different studied factors. The maximum value of discoloration under the optimum operating conditions was determined to be 99% after 300 min of UV irradiation.

Optimization of multiple-quality characteristics in micro-WEDG process using Taguchi technique

Purpose

– Micro-EDM is an important process in the field of micro-machining. Especially, theμEDM is one of the technologies widely used for manufacture of micro-parts, micro-tools and micro-components, etc. The accuracy and repeatability of theμEDM process is still highly dependent on theμWEDG process. The electrode generation and regeneration is considered a key enabling technology for improving the performance of theμEDM process. Many engineers considered the Taguchi technique as engineering judgment during multiple response optimizations. This paper aims to focus on the use of micro-WEDG process to generate a micro-tool (electrode) with minimum surface roughness and higher metal removal rate (MRR).

Design/methodology/approach

– In this research work, the Taguchi quality loss function analysis is used to examine and explain the influences of three process parameters (feed rate, capacitance and voltage) on the output responses such as MRR and surface roughness. Further, the optimized machining parameters were determined considering the multiple response objective using Taguchi multi-response signal-to-noise ratio.

Findings

– Based on the experimental result, it was concluded that the Taguchi technique is suitable for the optimization of multi-response problem.

Originality/value

– This paper presents an alternative approach using Taguchi's quality loss function. In most of the modern technological situations, more than one response variable is pertinent to the success of an industrial process. In this research work, the influence of feed rate, capacitance and voltage on the MRR and surface roughness (multiple responses) is investigated.