Methodological study on technology integration for sustainable manufacturing in the surface finishing industry

Today, industries explore advanced techniques to enhance their development efforts to meet the goals of sustainability due to various challenges which is caused by industrial globalization, high energy and raw material costs, increased environmental regulations and social pressures, and new technological innovations. In order for an industrial process to become sustainable, it is essential to improve the process inputs efficiency from raw materials and energy while maintaining highest productivity and quality; in addition to, minimizing waste generation and the impact on the environment. Engaging in industrial sustainability requires major efforts from decision makers to implement advanced technologies to satisfy each triple bottom line of sustainability. Due to the complexity of industrial systems and lack of quantifiable mechanisms to assess sustainability triple bottom lines, decision makers are facing a very difficult task to solve. In this research a holistic methodology for sustainability assessment and decision-making is developed, which will assist in improving the sustainability level through implementing and integrating sustainable technologies in manufacturing systems through case studies, particularly on the electroplating industry. The methodology is general but our intent is to apply it to electroplating metal substrate processes. This research is valuable in its methodological contribution for sustainability assessment, decision-making, and technology quantification via known and well established sustainability metrics to assist decision makers to identify desired technologies needed for improving overall industrial sustainability development. This methodology is applicable for any type of industrial system of any complexity, and its efficacy is demonstrated in a case study identifying desired technologies and their implementation for achieving an overall sustainable level enhancement. Moreover, a computer aided computational tool is developed for industry forecasters to assess their current industrial sustainability and determine future sustainability goals in a quantitative manner using an interactive graphical user interface. To the best of our knowledge the introduced concept of technology integrated sustainability enhancement (TISE) holistic approach is the first to be used to effectively enhance the overall industrial system sustainability by evaluating each technology or suite of technologies based on strategically selected indicators and combined benefits methodology assessment. Furthermore, an optimization based approach was introduced for a proficient sustainability assessment of industrial systems via technology integration. Another major contribution in this research is the development of an industrial sustainability assessment program using LabView software and Matlab programming tools to assess the sustainability of various technology options. The assessment results from this program provide different technology integration options and alternatives which can be compared in terms of sustainability triple bottom lines, overall sustainability performance, and the optimum solution can be identified as the one yielding to the highest sustainability value depending on budget cost limitation to implement those technologies

Advancements in sustainable natural dyes for textile applications: a review

The dyeing and finishing step represents a clear hotspot in the textile supply chain as the wet processing stages require significant amounts of water, energy, and chemicals. In order to tackle environmental issues, natural dyes are gaining attention from researchers as more sustainable alternatives to synthetic ones. This review discusses the topic of natural dyes, providing a description of their main features and differences compared to synthetic dyes, and encompasses a summary of recent research in the field of natural dyes with specific reference to the following areas of sustainable innovation: extraction techniques, the preparation of substrates, the mordanting process, and the dyeing process. The literature review showed that promising new technologies and techniques have been successfully employed to improve the performance and sustainability of natural dyeing processes, but several limitations such as the poor fastness properties of natural dyes, their low affinity with textiles substrates, difficulties in the reproducibility of shades, as well as other factors such as cost-effectiveness considerations, still prevent industry from adopting natural dyes on a larger scale and will require further research in order to expand their use beyond niche applicationsThis work was funded by AGAUR within the OliWasTex project (2021-PROD00074)Objectius de Desenvolupament Sostenible::9 - Indústria, Innovació i InfraestructuraObjectius de Desenvolupament Sostenible::9 - Indústria, Innovació i Infraestructura::9.4 - Per a 2030, modernitzar les infraestructures i reconvertir les indústries perquè siguin sostenibles, usant els recursos amb més eficàcia i promovent l’adopció de tecnologies i processos industrials nets i racionals ambiental­ment, i aconseguint que tots els països adoptin mesures d’acord amb les capacitats respectivesObjectius de Desenvolupament Sostenible::12 - Producció i Consum ResponsablesObjectius de Desenvolupament Sostenible::12 - Producció i Consum Responsables::12.5 - Per a 2030, disminuir de manera substancial la generació de residus mitjançant polítiques de prevenció, reducció, reciclatge i reutilitzacióObjectius de Desenvolupament Sostenible::12 - Producció i Consum Responsables::12.2 - Per a 2030, assolir la gestió sostenible i l’ús eficient dels recursos naturalsObjectius de Desenvolupament Sostenible::12 - Producció i Consum Responsables::12.4 - Per a 2020, aconseguir la gestió ecològicament racional dels productes químics i de tots els residus al llarg del seu cicle de vida, de conformitat amb els marcs internacionals convinguts, i reduir-ne de manera significativa l’alliberament a l’atmosfera, a l’aigua i al sòl a fi de minimitzar-ne els efectes adversos sobre la salut humana i el medi ambientPostprint (published version

SciTech News Volume 71, No. 2 (2017)

Columns and Reports From the Editor 3 Division News Science-Technology Division 5 Chemistry Division 8 Engineering Division 9 Aerospace Section of the Engineering Division 12 Architecture, Building Engineering, Construction and Design Section of the Engineering Division 14 Reviews Sci-Tech Book News Reviews 16 Advertisements IEEE

A comprehensive evaluation of physical and environmental performances for wet-white leather manufacture

This paper presents the comprehensive evaluation results of physical and environmental performances for a novel wet-white (chrome-free) leather manufacturing. The tanning process is optimized as 15 wt% tannic acid (TA) combination with 4 wt% Laponite nanoclay, giving the leather with shrinkage temperature (Ts) above 86 °C. Inductively coupled plasma-atomic emission spectrometry (ICP-AES) measurements indicate that Laponite can be evenly and tightly bound within the leather matrix, which is further confirmed by scanning electron microscopy and energy dispersive X-ray (SEM-EDX) spectroscopy analysis. The resultant wet-white leathers have reasonable good physical properties that can meet the standard requirements for furniture leather without containing hazardous Cr(VI) and formaldehyde. Further life cycle assessment (LCA) studies shows that tanning process is the main contributor to environmental impact categories in the wet-white tanning process, and tannic acid is the most significant substance factor. Compared to conventional chrome tanning, the wet-white tanning process exhibits much lower abiotic depletion potential (ADP), and reduced global warming potential (GWP) and human toxicity potential (HTP) impacts due to the nature of vegetable tanning; whereas, GWP excluding biogenic carbon and energy consumption are higher owing to prolonged run time.Peer ReviewedPostprint (published version

Sustainability Issues of Various Denim Washing Methods

Denim washing is increasingly joining the list of indispensable processes of meeting the demands of the world’s shifting fashion industry. Other than this, there is a rising trend in the sustainability perception among both producers and customers in the modern world. However, denim washing is considered to have direct impacts on the environment because of its chemical discharge and many other pollutants emitted during the process which affect water supplies. In the process, the denim industry encounters challenges at every level. Therefore, there is need for studying sustainable problems associated with denim washing. The unseen soul of the denim industry is technology, as nothing can be transformed without technological advancement. Sustainability problems of conventional washing have been addressed in this paper (i.e. pp spray washing, bleaching washing, stone washing, sand blasting etc.). Furthermore, the paper describes how sustainability can be achieved through the most recent washing techniques, such as laser, waterjet, nanobubble, ozone, NoStone, potassium permanganate alternatives etc. The introduction of new technologies has triggered a dramatic shift in the denim washing industry in terms of water usage, electricity and chemicals as well as improved quality. Consequently, it is undoubtful that the recent technologies in denim washing are crucial in making the industry sustainable. Moreover, the paper describes the idea of digitally printed denim and the available software for measuring sustainability in the process of denim washing

A Review on Application of Natural Dyes on Textile Fabrics and Its Revival Strategy

A comprehensive review on application of natural dyes on textiles and earlier research findings has been discussed in this chapter. Moreover, recently the consumers have become very much conscious about the environment, renaissance of eco-friendly products and process like dyeing textiles with natural dyes, which has thus become also important now. Thus, revival of natural dye application on textiles and summary of earlier researches on standardization of its method of extraction, mordanting, dyeing process variables and even natural finishing, etc. have been elaborated in this review. Characterization of natural dyes and chemistry of its dyeing, etc. are equally important and hence are discussed here critically. Thus this part has become a unique readymade comprehensive chapter for information on chemistry and application of natural dyes on textiles and its revival strategy

Utilization of Banana Extract for Eco-friendly Functional Finishing of Textile Materials: A review

With the consumer's enhanced awareness of eco-safety, there has been an increasing tendency towards the use of sustainable and environmentally friendly materials. Thus considerable attention has been given to products from plants, for use in various industries notably in the textile industry. Among these plants banana is selected for this review, since it is the second largest produced fruit after citrus, contributing about 16% of the world’s total fruit production. This review provides literature information about classification of functional finishing, some important finishes, and their evaluation tests methods. In addition to focus on recent researches concerning utilization and application of banana extract for various textile finishing purposes such as coloration, deodorizing, flame retardant, UV protection, antimicrobial activity, and other important applications around the world for producing appealing and highly functional value-added textiles such as fibers, dyes , pigments, polyphenols, and other biologically active compounds. &nbsp

Eco-efficient process based on conventional machining as an alternative technology to chemical milling of aeronautical metal skin panels

El fresado químico es un proceso diseñado para la reducción de peso de pieles metálicas que, a pesar de los problemas medioambientales asociados, se utiliza en la industria aeronáutica desde los años 50. Entre sus ventajas figuran el cumplimiento de las estrictas tolerancias de diseño de piezas aeroespaciales y que pese a ser un proceso de mecanizado, no induce tensiones residuales. Sin embargo, el fresado químico es una tecnología contaminante y costosa que tiende a ser sustituida. Gracias a los avances realizados en el mecanizado, la tecnología de fresado convencional permite alcanzar las tolerancias requeridas siempre y cuando se consigan evitar las vibraciones y la flexión de la pieza, ambas relacionadas con los parámetros del proceso y con los sistemas de utillaje empleados. Esta tesis analiza las causas de la inestabilidad del corte y la deformación de las piezas a través de una revisión bibliográfica que cubre los modelos analíticos, las técnicas computacionales y las soluciones industriales en estudio actualmente. En ella, se aprecia cómo los modelos analíticos y las soluciones computacionales y de simulación se centran principalmente en la predicción off-line de vibraciones y de posibles flexiones de la pieza. Sin embargo, un enfoque más industrial ha llevado al diseño de sistemas de fijación, utillajes, amortiguadores basados en actuadores, sistemas de rigidez y controles adaptativos apoyados en simulaciones o en la selección estadística de parámetros. Además se han desarrollado distintas soluciones CAM basadas en la aplicación de gemelos virtuales. En la revisión bibliográfica se han encontrado pocos documentos relativos a pieles y suelos delgados por lo que se ha estudiado experimentalmente el efecto de los parámetros de corte en su mecanizado. Este conjunto de experimentos ha demostrado que, pese a usar un sistema que aseguraba la rigidez de la pieza, las pieles se comportaban de forma diferente a un sólido rígido en términos de fuerzas de mecanizado cuando se utilizaban velocidades de corte cercanas a la alta velocidad. También se ha verificado que todas las muestras mecanizadas entraban dentro de tolerancia en cuanto a la rugosidad de la pieza. Paralelamente, se ha comprobado que la correcta selección de parámetros de mecanizado puede reducir las fuerzas de corte y las tolerancias del proceso hasta un 20% y un 40%, respectivamente. Estos datos pueden tener aplicación industrial en la simplificación de los sistemas de amarre o en el incremento de la eficiencia del proceso. Este proceso también puede mejorarse incrementando la vida de la herramienta al utilizar fluidos de corte. Una correcta lubricación puede reducir la temperatura del proceso y las tensiones residuales inducidas a la pieza. Con este objetivo, se han desarrollado diferentes lubricantes, basados en el uso de líquidos iónicos (IL) y se han comparado con el comportamiento tribológico del par de contacto en seco y con una taladrina comercial. Los resultados obtenidos utilizando 1 wt% de los líquidos iónicos en un tribómetro tipo pin-on-disk demuestran que el IL no halogenado reduce significativamente el desgaste y la fricción entre el aluminio, material a mecanizar, y el carburo de tungsteno, material de la herramienta, eliminando casi toda la adhesión del aluminio sobre el pin, lo que puede incrementar considerablemente la vida de la herramienta.Chemical milling is a process designed to reduce the weight of metals skin panels. This process has been used since 1950s in the aerospace industry despite its environmental concern. Among its advantages, chemical milling does not induce residual stress and parts meet the required tolerances. However, this process is a pollutant and costly technology. Thanks to the last advances in conventional milling, machining processes can achieve similar quality results meanwhile vibration and part deflection are avoided. Both problems are usually related to the cutting parameters and the workholding. This thesis analyses the causes of the cutting instability and part deformation through a literature review that covers analytical models, computational techniques and industrial solutions. Analytics and computational solutions are mainly focused on chatter and deflection prediction and industrial approaches are focused on the design of workholdings, fixtures, damping actuators, stiffening devices, adaptive control systems based on simulations and the statistical parameters selection, and CAM solutions combined with the use of virtual twins applications. In this literature review, few research works about thin-plates and thin-floors is found so the effect of the cutting parameters is also studied experimentally. These experiments confirm that even using rigid workholdings, the behavior of the part is different to a rigid body at high speed machining. On the one hand, roughness values meet the required tolerances under every set of the tested parameters. On the other hand, a proper parameter selection reduces the cutting forces and process tolerances by up to 20% and 40%, respectively. This fact can be industrially used to simplify workholding and increase the machine efficiency. Another way to improve the process efficiency is to increase tool life by using cutting fluids. Their use can also decrease the temperature of the process and the induced stresses. For this purpose, different water-based lubricants containing three types of Ionic Liquids (IL) are compared to dry and commercial cutting fluid conditions by studying their tribological behavior. Pin on disk tests prove that just 1wt% of one of the halogen-free ILs significantly reduces wear and friction between both materials, aluminum and tungsten carbide. In fact, no wear scar is noticed on the ball when one of the ILs is used, which, therefore, could considerably increase tool life

Simulation based energy and resource efficient casting process chain selection: a case study

Casting processes are among the most energy intensive manufacturing processes. A typical modern casting process contains different stages, classified as melting-alloying, moulding, pouring, solidification, fettling, machining and finishing respectively. At each stage, large amounts of energy are consumed. Since a number of different casting processes exist, it is not always straightforward which process chain to select among the available ones. Up to now the selection is based on cost criteria. This paper focuses on the different criteria that needs to be considered and how they can be simulated focusing especially on the energy and resource efficiency of casting stages. A disruptive technology that uses a rapid induction furnace to melt just enough metal for a single mould rather than bulk melting used in traditional processing is proposed and validated

Environmental Impact Assessment Studies in Additive Manufacturing

International audienceThis chapter focuses on the environmental studies in additive manufacturing. For a cleaner production, environmental impacts that occur during the manufacturing phase should be assessed with accuracy. First, the literature on all the studies led to the characterization of the environmental impact of additive manufacturing processes. The studies on electric energy consumption of these processes are analyzed here, and then some studies taking into account raw material and all the flows through the process are detailed. Secondly, a new methodology in order to evaluate, with accuracy, the environmental impact of a part from its CAD model is presented. In this methodology, the work is not focused only on electrical consumption but also on fluids and material consumption which also contribute to the environmental impact. In addition, the inputs of this methodology correspond to the set part process, which allows taking into account different manufacturing strategies and their influences on the global environmental impact. The methodology developed is based on both analytic models (validated by experiments) and experimental models. And finally, an industrial example shows that for some manufacturing strategies, the environmental impact due to electrical consumption is not the predominant one. In this case study, material consumption has an important impact and has to be taken into consideration for a complete environmental impact assessment