Anaerobic treatment of complex chemical wastewater in a sequencing batch biofilm reactor: process optimization and evaluation of factor interactions using the Taguchi dynamic DOE methodology

The Taguchi robust experimental design (DOE) methodology has been applied on a dynamic anaerobic process treating complex wastewater by an anaerobic sequencing batch biofilm reactor (AnSBBR). For optimizing the process as well as to evaluate the influence of different factors on the process, the uncontrollable (noise) factors have been considered. The Taguchi methodology adopting dynamic approach is the first of its kind for studying anaerobic process evaluation and process optimization. The designed experimental methodology consisted of four phases--planning, conducting, analysis, and validation connected sequence-wise to achieve the overall optimization. In the experimental design, five controllable factors, i.e., organic loading rate (OLR), inlet pH, biodegradability (BOD/COD ratio), temperature, and sulfate concentration, along with the two uncontrollable (noise) factors, volatile fatty acids (VFA) and alkalinity at two levels were considered for optimization of the anae robic system. Thirty-two anaerobic experiments were conducted with a different combination of factors and the results obtained in terms of substrate degradation rates were processed in Qualitek-4 software to study the main effect of individual factors, interaction between the individual factors, and signal-to-noise (S/N) ratio analysis. Attempts were also made to achieve optimum conditions. Studies on the influence of individual factors on process performance revealed the intensive effect of OLR. In multiple factor interaction studies, biodegradability with other factors, such as temperature, pH, and sulfate have shown maximum influence over the process performance. The optimum conditions for the efficient performance of the anaerobic system in treating complex wastewater by considering dynamic (noise) factors obtained are higher organic loading rate of 3.5 Kg COD/m3 day, neutral pH with high biodegradability (BOD/COD ratio of 0.5), along with mesophilic temperature range (40 degrees C), and low sulfate concentration (700 mg/L). The optimization resulted in enhanced anaerobic performance (56.7%) from a substrate degradation rate (SDR) of 1.99 to 3.13 Kg COD/m3 day. Considering the obtained optimum factors, further validation experiments were carried out, which showed enhanced process performance (3.04 Kg COD/m3-day from 1.99 Kg COD/m3 day) accounting for 52.13% improvement with the optimized process conditions. The proposed method facilitated a systematic mathematical approach to understand the complex multi-species manifested anaerobic process treating complex chemical wastewater by considering the uncontrollable factors.     

Application of Taguchi method in optimization of cervical ring cage

The Taguchi method is a statistical approach to overcome the limitation of the factorial and fractional factorial experiments by simplifying and standardizing the fractional factorial design. The objective of the current study is to illustrate the procedures and strengths of the Taguchi method in biomechanical analysis by using a case study of a cervical ring cage optimization. A three-dimensional finite element (FE) model of C(5)-C(6) with a generic cervical ring cage inserted was modelled. Taguchi method was applied in the optimization of the cervical ring cage in material property and dimensions for producing the lowest stress on the endplate to reduce the risk of cage subsidence, as in the following steps: (1) establishment of objective function; (2) determination of controllable factors and their levels; (3) identification of uncontrollable factors and test conditions; (4) design of Taguchi crossed array layout; (5) execution of experiments according to trial conditions; (6) analysis of results; (7) determination of optimal run; (8) confirmation of optimum run. The results showed that a cage with larger width, depth and wall thickness can produce the lower von Mises stress under various conditions. The contribution of implant materials is found trivial. The current case study illustrates that the strengths of the Taguchi method lie in (1) consistency in experimental design and analysis; (2) reduction of time and cost of experiments; (3) robustness of performance with removing the noise factors. The Taguchi method will have a great potential application in biomechanical field when factors of the issues are at discrete level.     

Taguchi approach significantly increases bioremediation process efficiency: a case study with Hg (II) removal by Pseudomonas aeruginosa

AIM: Optimization of process parameters for mercury removal by an Hg (II)-reducing Pseudomonas aeruginosa strain. METHODS AND RESULTS: A strain of Ps. aeruginosa was found to reduce 10 mg l(-1) Hg (II) to Hg0 with 70% efficiency in 24 h. To optimize process performance, a statistical tool--Taguchi design of experiments (DOE)--was used to carry out 18 well-defined experiments (L18 Orthogonal array) with eight variable parameters (viz. agitation, temperature, pH, carbon source, medium volume: flask volume ratio and concentrations of Hg (II), ammonium sulfate and yeast extract). When data obtained were analyzed using specialized software for Taguchi design, Qualitek-4 (Nutek Inc., MI, USA), Hg (II) reduction efficiency was predicted to be 95% in 24 h under the optimized process parameters (also suggested by the software). In the validation experiment, Hg (II) removal of 99.29% in 24 h was indeed obtained. CONCLUSIONS: Using Taguchi DOE, Hg (II) reduction (and hence its removal) using Ps. aeruginosa could be improved by 29.3%. SIGNIFICANCE AND IMPACT OF THE STUDY: Taguchi approach could be employed as an efficient and time-saving strategy for parameter optimization in bioremediation processes.     

Alkaline protease production by an isolated Bacillus circulans under solid-state fermentation using agroindustrial waste: process parameters optimization

Alkaline protease production using isolated Bacillus circulans under solid-state fermentation environment was optimized by using Taguchi orthogonal array (OA) experimental design (DOE) methodology to understand the interaction of a large number of variables spanned by factors and their settings with a small number of experiments in order to economize the process optimization. The software-designed experiments with an OA worksheet of L-27 was selected to optimize fermentation (temperature, particle size, moisture content and pH), nutrition (yeast extract and maltose), and biomaterial-related (inoculum size and incubation time) factors for the best production yields. Analysis of experimental data using Qualitek-4 methodology showed significant variation in enzyme production levels (32,000-73,000 units per gram material) and dependence on the selected factors and their assigned levels. Validation of experimental results on alkaline protease production by this bacterial strain based on DOE methodology revealed 51% enhanced protease production compared to average performance of the fermentation, indicating the importance of this methodology in the evaluation of main and interaction effects of the selected factors individually and in combination for bioprocess optimization.     

Selection of best conditions of inoculum preparation for optimum performance of the pigment production process by Talaromyces spp. using the Taguchi method

Process optimisation techniques increasingly need to be used early on in research and development of processes for new ingredients. There are different approaches and this article illustrates the main issues at stake with a method that is an industry best practice, the Taguchi method, suggesting a procedure to assess the potential impact of its drawbacks. The Taguchi method has been widely used in various industrial sectors because it minimises the experimental requirements to define an optimum region of operation, which is particularly relevant when minimising variability is a target. However, it also has drawbacks, especially the intricate confoundings generated by the experimental designs used. This work reports a process optimisation of the synthesis of red pigments by a fungal strain, Talaromyces spp. using the Taguchi methodology and proposes an approach to assess from validation trials whether the conclusions can be accepted with confidence. The work focused on optimising the inoculum characteristics, and the studied factors were spore age and concentration, agitation speed and incubation time. It was concluded that spore age was the most important factor for both responses, with optimum results at 5 days old, with the best other conditions being spores concentration, 100,000 (spores/mL); agitation, 200 rpm; and incubation time, 84 h. The interactive effects can be considered negligible and therefore this is an example where a simple experimental design approach was successful in speedily indicating conditions able to increase pigment production by 63% compared to an average choice of settings. © 2017 American Institute of Chemical Engineers Biotechnol. Prog., 33:621–632, 2017     

Systematic experimental design for bioprocess characterization: Elucidating transient effects of multi-cytokine contributions on erythroid differentiation

In vitro differentiation of hematopoietic stem cells (HSCs) is a highly dynamic process whereby contributions of exogenous cytokines vary at each stage of differentiation. In this study, we present erythroid differentiation as three progressive yet independent stages and aim to elucidate transient contributions from stem cell factor (SCF), insulin-growth factor II (IGF-II), and erythropoietin (EPO). This will be accomplished using the Taguchi design and response surface methodology (RSM). We found that cultures with high process variability (noise factors), such as those in primary cell cultures, pose limitations on the effectiveness of RSM and result in inconsistencies in empirical models developed for elucidating transient effects. However, the Taguchi design—which showed greater robustness in accommodating for noise factors—successfully identified significant main and interactive contributions at each differentiation stage, thus highlighting the dynamic roles of each cytokine. The Taguchi analysis suggested high IGF-II dependency during early erythroid differentiation, with an antagonistic effect in the presence of EPO. At mid-stage differentiation, the roles of SCF and EPO dominate those of IGF-II, and the former act independently. Finally, toward erythroid maturation, only EPO plays a significant role. Although process outcomes from the Taguchi analysis were semi-quantitative, this approach provides a path for overcoming cell culture and sample-to-sample variability and can therefore be utilized with many cell culture applications in order to understandcomplex and intricate process relationships.     

Design of experiments applications in bioprocessing: Chromatography process development using split design of experiments

Development of a chromatographic step in a time and resource efficient manner remains a serious bottleneck in protein purification. Chromatographic performance typically depends on raw material attributes, feed material attributes, process factors, and their interactions. Design of experiments (DOE) based process development is often chosen for this purpose. A challenge is, however, in performing a DOE with such a large number of process factors. A split DOE approach based on process knowledge in order to reduce the number of experiments is proposed. The first DOE targets optimizing factors that are likely to significantly impact the process and their effect on process performance is unknown. The second DOE aims to fine-tune another set of interacting process factors, impact of whom on process performance is known from process understanding. Furthermore, modeling of a large set of output response variables has been achieved by fitting the output responses to an empirical equation and then using the parametric constants of the equation as output response variables for regression modeling. Two case studies involving hydrophobic interaction chromatography for removal of aggregates and cation exchange chromatography for separation of charge variants and aggregates have been utilized to illustrate the proposed approach. Proposed methodology reduced total number of experiments by 25% and 72% compared to a single DOE based on central composite design and full factorial design, respectively. The proposed approach is likely to result in a significant reduction in resources required as well as time taken during process development. © 2018 American Institute of Chemical Engineers Biotechnol. Prog., 35: e2730, 2019     

Assembly Process Design for Managing Manufacturing Complexities Because of Product Varieties

This paper comprehensively studies assembly process design (APD) to handle variety and presents a new approach to strategically manage manufacturing complexities because of product varieties. It links the chronological steps of APD to a general approach with a view to reduce both short and long term wastes. It synthesizes two strategic approaches, product and process-based, while exploiting the APD of an entire product family. A new evaluation method for measuring the complexities of an assembly system at different stages of design has been introduced by applying information entropy. The developed evaluation methodology explains the available techniques related to design, interprets them from a design for variety point of view, and leads to techniques to manage complexities in manufacturing. The suggested methodology has been applied to examples from automobile part manufacturers and has been found to be effective in understanding the complexities in manufacturing and leading to some strategies to manage variety.     

Finite element analyses for improved design of peripheral stents

Due to the recent increase in the number of stent insertion procedures, the number of studies to evaluate the mechanical behaviors of stents, such as the stress and deformation states, using finite element analysis is also increasing. However, it is still not easy to design stents that are uniformly expanded and show enough radial strength and flexibility. Therefore, in this study, the Taguchi method and finite element analysis were used to determine a set of optimal design variables for unit patterns of stents, and a new design approach was developed to realize uniform expansion, enough radial strength and good flexibility. The stent designed using the new design approach was verified by experiments.     

Optimizing the spectrofluorimetric determination of cefdinir through a Taguchi experimental design approach

The aim of this work is to optimize a spectrofluorimetric method for the determination of cefdinir (CFN) using the Taguchi method. The proposed method is based on the oxidative coupling reaction of CFN and cerium(IV) sulfate. The quenching effect of CFN on the fluorescence of the produced cerous ions is measured at an emission wavelength (λ_em) of 358 nm after excitation (λ_ex) at 301 nm. The Taguchi orthogonal array L₉ (3⁴) was designed to determine the optimum reaction conditions. The results were analyzed using the signal‐to‐noise (S/N) ratio and analysis of variance (ANOVA). The optimal experimental conditions obtained from this study were 1 mL of 0.2% MBTH, 0.4 mL of 0.25% Ce(IV), a reaction time of 10 min and methanol as the diluting solvent. The calibration plot displayed a good linear relationship over a range of 0.5–10.0 µg/mL. The proposed method was successfully applied to the determination of CFN in bulk powder and pharmaceutical dosage forms. The results are in good agreement with those obtained using the comparison method. Finally, the Taguchi method provided a systematic and efficient methodology for this optimization, with considerably less effort than would be required for other optimizations techniques. Copyright © 2015 John Wiley & Sons, Ltd.     

Design of experiments applications in bioprocessing: Concepts and approach

Most biotechnology unit operations are complex in nature with numerous process variables, feed material attributes, and raw material attributes that can have significant impact on the performance of the process. Design of experiments (DOE)‐based approach offers a solution to this conundrum and allows for an efficient estimation of the main effects and the interactions with minimal number of experiments. Numerous publications illustrate application of DOE towards development of different bioprocessing unit operations. However, a systematic approach for evaluation of the different DOE designs and for choosing the optimal design for a given application has not been published yet. Through this work we have compared the I‐optimal and D‐optimal designs to the commonly used central composite and Box–Behnken designs for bioprocess applications. A systematic methodology is proposed for construction of the model and for precise prediction of the responses for the three case studies involving some of the commonly used unit operations in downstream processing. Use of Akaike information criterion for model selection has been examined and found to be suitable for the applications under consideration. © 2013 American Institute of Chemical Engineers Biotechnol. Prog., 30:86–99, 2014     

Chemometric analysis of lipase-catalyzed synthesis of xylitol esters in a solvent-free system

Immobilized Candida antarctica lipase B-catalyzed esterification of xylitol and two fatty acids (capric and caproic acid) were studied in a solvent-free system. The Taguchi orthogonal array method based on three-level-four-variables with nine experiments was applied for the analysis and optimization of the reaction parameters including time, substrate molar ratio, amount of enzyme, and amount of molecular sieve. The obtained conversion was higher in the esterification of xylitol and capric acid with longer chain length. The optimum conditions derived via the Taguchi approach for the synthesis of xylitol caprate and xylitol caproate were reaction time, 29 and 18 h; substrate molar ratio, 0.3 and 1.0; enzyme amount, 0.20 and 0.05 g, and molecular sieve amount of 0.03 g, respectively. The good correlation between the predicted conversions (74.18% and 61.23%) and the actual values (74.05% and 60.5%) shows that the model derived from the Taguchi orthogonal array can be used for optimization and better understanding of the effect of reaction parameters on the enzymatic synthesis of xylitol esters in a solvent-free system.     

Evolutionary operation (EVOP) to optimize protease biosynthesis by Rhizopus oryzae

To optimize the operating conditions of any microbial process, evolutionary operation (EVOP) technique can be applied as a tool. This is very efficient to optimize the combined effect of two or three variables and their interaction on a biological process. The application of EVOP methodology to optimize the environmental conditions for any biological system has not yet been reported in the literature. In this paper firstly EVOP methodology for optimizing two-variable experiments has been outlined and then applied to optimize protease biosynthesis by Rhizopus oryzae (RO, IIT KGP).     

Application of type synthesis theory to the redesign of a complex surgical instrument

Surgical instruments consist of basic mechanical components such as gears, links, pivots, sliders, etc., which are common in mechanical design. This paper describes the application of a method in the analysis and design of complex surgical instruments such as those employed in laparoscopic surgery. This is believed to be the first application of type synthesis theory to a complex medical instrument. Type synthesis is a methodology that can be applied during the conceptual phase of mechanical design. A handle assembly from a patented laparoscopic surgical stapler is used to illustrate the application of the design method developed. Type synthesis is applied on specific subsystems of the mechanism within the handle assembly where alternative design concepts are generated. Chosen concepts are then combined to form a new conceptual design for the handle assembly. The new handle assembly is improved because it has fewer number of parts, is a simpler design and is easier to assemble. Surgical instrument designers may use the methodology presented here to analyze the mechanical subsystems within complex instruments and to create new options that may offer improvements to the original design.     

Towards robust cell culture processes — Unraveling the impact of media preparation by spectroscopic online monitoring

Biopharmaceutical manufacturing processes can be affected by variability in cell culture media, e.g. caused by raw material impurities. Although efforts have been made in industry and academia to characterize cell culture media and raw materials with advanced analytics, the process of industrial cell culture media preparation itself has not been reported so far. Within this publication, we first compare mid‐infrared and two‐dimensional fluorescence spectroscopy with respect to their suitability as online monitoring tools during cell culture media preparation, followed by a thorough assessment of the impact of preparation parameters on media quality. Through the application of spectroscopic methods, we can show that media variability and its corresponding root cause can be detected online during the preparation process. This methodology is a powerful tool to avoid batch failure and is a valuable technology for media troubleshooting activities. Moreover, in a design of experiments approach, including additional liquid chromatography–mass spectrometry analytics, it is shown that variable preparation parameters such as temperature, power input and preparation time can have a strong impact on the physico‐chemical composition of the media. The effect on cell culture process performance and product quality in subsequent fed‐batch processes was also investigated. The presented results reveal the need for online spectroscopic methods during the preparation process and show that media variability can already be introduced by variation in media preparation parameters, with a potential impact on scale‐up to a commercial manufacturing process.     

Dual transformation of homonuclear solid-state NMR spectra--an option to decrease measuring time

Long measurement times due to low sensitivity are a prime concern in solid-state NMR and limit the application of multidimensional experiments severely. One possibility to address this problem could be post-experimental suppression of noise and a reduction of the number of increments needed for higher dimensional data sets. This can be achieved by a hybrid approach based on the combination of separately Fourier transformed and covariance processed datasets. The method is applied to synthetic sets as well as to experimental two-dimensional homonuclear solid-state NMR spectra of peptide samples. It is demonstrated that a reduction in experiment time by a factor of 4 can be achieved for the case of a 13C-13C correlation spectrum on the nonapeptide bradykinin.     

maSigPro: a method to identify significantly differential expression profiles in time-course microarray experiments

MOTIVATION: Multi-series time-course microarray experiments are useful approaches for exploring biological processes. In this type of experiments, the researcher is frequently interested in studying gene expression changes along time and in evaluating trend differences between the various experimental groups. The large amount of data, multiplicity of experimental conditions and the dynamic nature of the experiments poses great challenges to data analysis. RESULTS: In this work, we propose a statistical procedure to identify genes that show different gene expression profiles across analytical groups in time-course experiments. The method is a two-regression step approach where the experimental groups are identified by dummy variables. The procedure first adjusts a global regression model with all the defined variables to identify differentially expressed genes, and in second a variable selection strategy is applied to study differences between groups and to find statistically significant different profiles. The methodology is illustrated on both a real and a simulated microarray dataset.     

Optimization of an anti-HER2 nanobody expression using the Taguchi method

Despite being widely used in immunotherapy of cancer, whole antibodies are limited by several disadvantages. This has led to the advent of novel biomolecules such as nanobodies. Taguchi method is a statistical experimental design to study the effect of multiple variables in biological processes. In an effort to overexpress a recombinant anti-human epidermal growth factor receptor type 2 (HER2) nanobody, we performed a detailed study to find optimal condition of temperature, induction, culture media, vector, and host strain, using Taguchi methodology. A total of 16 various experiments were designed. Total protein of the formulated cultures were assessed by Bradford test and sodium dodecyl sulfate-polyacrylamide gel electrophoresis, followed by size exclusion high performance liquid chromatography to quantify the relative concentration of the nanobody in different expression settings. Western blotting was performed to confirm the expression of the anti-HER2 nanobody. When, individually, optimum parameters determined by Taguchi were applied, including SHuffle strain cultured in LB medium, induced with 0.4?mM isopropyl-β-D-thio-galactoside for 18?h at 24°C, production yield further increased by about 9% (25.4?mg/L), compared to the highest expression setting. Flow cytometry and enzyme-linked immunosorbent assay result indicated improved protein binding in optimized conditions. Overall, our findings provide a basis for further investigations on economical production of recombinant nanobodies to improve production yield and activity.     

Efficient optimization of time-varying inputs in a fed-batch cell culture process using design of dynamic experiments

In cell culture process development, we rely largely on an iterative, one-factor-at-a-time procedure based on experiments that explore a limited process space. Design of experiments (DoE) addresses this issue by allowing us to analyze the effects of process inputs on process responses systematically and efficiently. However, DoE cannot be applied directly to study time-varying process inputs unless an impractically large number of bioreactors is used. Here, we adopt the methodology of design of dynamic experiments (DoDE) and incorporate dynamic feeding profiles efficiently in late-stage process development of the manufacture of therapeutic monoclonal antibodies. We found that, for the specific cell line used in this article, (1) not only can we estimate the effect of nutrient feed amount on various product attributes, but we can also estimate the effect, develop a statistical model, and use the model to optimize the slope of time-trended feed rates; (2) in addition to the slope, higher-order dynamic characteristics of time-trended feed rates can be incorporated in the design but do not have any significant effect on the responses we measured. Based on the DoDE data, we developed a statistical model and used the model to optimize several process conditions. Our effort resulted in a tangible improvement in productivity—compared with the baseline process without dynamic feeding, this optimized process in a 200-L batch achieved a 27% increase in titer and > 92% viability. We anticipate our application of DoDE to be a starting point for more efficient workflows to optimize dynamic process conditions in process development.