Batch sizes and lead-time performance in flexible manufacturing systems

Production lead-time performance in flexible manufacturing systems is influenced by several factors which include: machine groupings, demand rates, machine processing rates, product batching, material handling system capacity, and so on. Hence, control of lead-time performance can be affected through the manipulation of one or more of these variables. In this article, we investigate the potential of batch sizing as a control variable for lead-time performance through the use of a queueing network model. We establish a functional relationship between the two variables, and incorporate the relationship in an optimization model to determine the optimal batch size(s) which minimizes the sum of annual work-in-process inventory and final inventory costs. The nonlinear batch sizing problem which results is solved by discrete optimization via marginal analysis. Results show that batch sizing can be a cheap and effective variable for controlling flexible manufacturing system throughput.     

Kinetic modeling of the autotrophic growth of Pavlova lutheri: study of the combined influence of light and temperature

The optimization and control of biochemical processes require the previous establishment of mathematical models that can describe the effect of process variables on their actual kinetics. Environmental temperature is a modulating factor to which the algal cells respond continuously by adjusting their rates of cellular reactions, their nutritional requirements, and, consequently, their biomass composition. Light intensity is an exhaustible resource, indispensable to autotrophic organisms. The effects of light intensity and temperature on growth of the microalga Pavlova lutheri, which have hardly been considered to date in a simultaneous fashion, were experimentally assessed using a factorial experimental design; in this way, the effects of each variable independently and their interactions could be quantified, using maximum biomass (X(max)) or maximum specific growth rate (mu(max)) as objective functions. The preliminary results produced indicated that light intensity plays a more important role on mu(max) than temperature; in the case of X(max), both temperature and, to a lesser extent, light intensity do apparently play a role. The highest values of X(max) were associated with low temperatures and high light intensities; a similar behavior could be observed for mu(max) concerning light intensity, although the dependency on temperature did not seem to be as important. A more complex mechanistic model was then postulated, incorporating light and temperature as input variables, which was successfully fitted to the experimental data generated during batch cultivation of P. lutheri.     

Phytoplankton thermal responses adapt in the absence of hard thermodynamic constraints

To better predict how populations and communities respond to climatic temperature variation, it is necessary to understand how the shape of the response of fitness-related rates to temperature evolves (the thermal performance curve). Currently, there is disagreement about the extent to which the evolution of thermal performance curves is constrained. One school of thought has argued for the prevalence of thermodynamic constraints through enzyme kinetics, whereas another argues that adaptation can—at least partly—overcome such constraints. To shed further light on this debate, we perform a phylogenetic meta-analysis of the thermal performance curves of growth rate of phytoplankton—a globally important functional group—controlling for environmental effects (habitat type and thermal regime). We find that thermodynamic constraints have a minor influence on the shape of the curve. In particular, we detect a very weak increase of maximum performance with the temperature at which the curve peaks, suggesting a weak “hotter-is-better” constraint. Also, instead of a constant thermal sensitivity of growth across species, as might be expected from strong constraints, we find that all aspects of the thermal performance curve evolve along the phylogeny. Our results suggest that phytoplankton thermal performance curves adapt to thermal environments largely in the absence of hard thermodynamic constraints.     

Evolution of thermal sensitivity of ectotherm performance

Most ectothermal animals have variable body temperatures. Because physiological rates are temperature sensitive, an ectotherm's behavioural and ecological performance - even its fitness - can be influenced by body temperature. As a result, the thermal sensitivity of ectotherm performance is relevant to diverse issues in physiology, ecology and evolution. This review formalizes an emerging framework for investigating the evolution of thermal sensitivity, outlines some functional and genetical constraints on that evolution, and summarizes comparative and experimental advances in this field.     

Biomechanical limits to ecological performance: mollusc-crushing by the Caribbean hogfish, Lachnolaimus maximus (Labridae)

Functional limitations on feeding ability were investigated in the mollusc-crushing Caribbean hogfish, Lachnolaimus maximus (Labridae). Two constraints were proposed to limit the maximum size prey L. maximus can eat: pharyngeal jaw gape and crushing force. These factors yield diflferent quantitative expectations for the relationship between fish size and maximum prey size. Their relative importance for predation on a frequently consumed gastropod ( Cerithium litteratum ) was investigated in laboratory performance tests designed to determine the largest snails fish could eat. Cerithium predation was found to be force limited rather than gape limited. The importance of this functional constraint in determining the largest Cerithium consumed by wild fish was examined by comparing hogfish feeding capability, as determined by the performance tests, to the maximum size snails found in the stomach contents of field-collected fish. Crushing ability appears to limit Cerithium predation in natural fish populations. The utility of performance testing for determining the functional and ecological importance of morphology is discussed.     

Comparison of a batch, fed-batch and continuously operated stirred-tank reactor for the enzymatic synthesis of (R)-mandelonitrile by using a process model

The suitability of a batch, fed-batch and continuously operated stirred-tank reactor for the enzymatic production of (R)-mandelonitrile in an aqueous-organic biphasic system was investigated by using a process model. The considered biphasic system is 10-50% (v/v) 100 mM sodium citrate buffer of pH 5.5 dispersed in methyl tert-butyl ether. The constraints were that 750 moles of benzaldehyde per cubic meter should react towards (R)-mandelonitrile with an enantiomeric excess of 99% and a conversion of 98%. A continuously operated stirred-tank reactor could not meet the constraints, but the production in a batch or fed-batch reactor was feasible. The choice for a batch or fed-batch reactor is dependent on the influence of the costs for reactor operation and for the enzyme on the product costs. The choice for operating at a small or large aqueous-phase volume fraction is dependent on the costs and reusability of the enzyme. The volumetric productivity is maximal when operating as batch. The enzymatic productivity and turnover are maximal when operating as fed batch. In the fed-batch mode, the enzymatic productivity increased by 24-37%, the turnover increased by 50-60% and the volumetric productivity decreased by 33-71% as compared to a batch reactor. By enhancement of mass transfer both the volumetric and enzymatic productivity can be increased considerably, while the turnover is only slightly decreased.     

Efficiency improvement of an antibody production process by increasing the inoculum density

Increasing economic pressure is the main driving force to enhance the efficiency of existing processes. We developed a perfusion strategy for a seed train reactor to generate a higher inoculum density for a subsequent fed batch production culture. A higher inoculum density can reduce culture duration without compromising product titers. Hence, a better capacity utilization can be achieved. The perfusion strategy was planned to be implemented in an existing large scale antibody production process. Therefore, facility and process constraints had to be considered. This article describes the initial development steps. Using a proprietary medium and a Chinese hamster ovary cell line expressing an IgG antibody, four different cell retention devices were compared in regard to retention efficiency and reliability. Two devices were selected for further process refinement, a centrifuge and an inclined gravitational settler. A concentrated feed medium was developed to meet facility constraints regarding maximum accumulated perfundate volume. A 2‐day batch phase followed by 5 days of perfusion resulted in cell densities of 1.6 × 10¹⁰ cells L^?1, a 3.5 fold increase compared to batch cultivations. Two reactor volumes of concentrated feed medium were needed to achieve this goal. Eleven cultivations were carried out in bench and 50 L reactors showing acceptable reproducibility and ease of scale up. In addition, it was shown that at least three perfusion phases can be combined within a repeated perfusion strategy. © 2014 American Institute of Chemical Engineers Biotechnol. Prog., 30:607–615, 2014     

Local divergence of thermal reaction norms among amphibian populations is affected by pond temperature variation

Although temperature variation is known to cause large‐scale adaptive divergence, its potential role as a selective factor over microgeographic scales is less well‐understood. Here, we investigated how variation in breeding pond temperature affects divergence in multiple physiological (thermal performance curve and critical thermal maximum [CT_max]) and life‐history (thermal developmental reaction norms) traits in a network of Rana arvalis populations. The results supported adaptive responses to face two main constraints limiting the evolution of thermal adaptation. First, we found support for the faster–slower model, indicating an adaptive response to compensate for the thermodynamic constraint of low temperatures in colder environments. Second, we found evidence for the generalist–specialist trade‐off with populations from colder and less thermally variable environments exhibiting a specialist phenotype performing at higher rates but over a narrower range of temperatures. By contrast, the local optimal temperature for locomotor performance and CT_max did not match either mean or maximum pond temperatures. These results highlight the complexity of the adaptive multiple‐trait thermal responses in natural populations, and the role of local thermal variation as a selective force driving diversity in life‐history and physiological traits in the presence of gene flow.     

An algorithm for adaptive control of dissolved oxygen concentration in batch culture

An effective automatic control algorithm for set-point control of dissolved oxygen concentration in batch culture has been developed. Adaptation of PI controller to the variable state of batch culture is based on analytically obtained functional relations between the controller parameters and the state variables: oxygen uptake rate, stirring speed, and saturation value of dissolved oxygen concentration, which are measured or estimated on-line. Results of experimental investigation of the adaptive control system are presented.     

High productivity of human recombinant beta-interferon from a low-temperature perfusion culture

Recombinant human interferon-beta (β-IFN), used in the therapeutic treatment of multiple sclerosis (MS), can be produced on a large-scale from genetically engineered Chinese hamster ovary (CHO) cells. However, its hydrophobicity causes non-reversible, molecular aggregation in culture. The parameters affecting aggregation were determined to be concentration, culture residence time, temperature and glycosylation. Although the protein can be produced in Escherichia coli in a non-glycosylated form, the addition of glycans confers a reduced rate of aggregation as well as a 10-fold higher bioactivity. We report on the application of a low temperature perfusion culture designed to control the parameters that cause aggregation. In this three-phase culture system there is a transition to a low temperature (32°C) in a batch mode prior to implementing perfusion at 1 volume/day using an acoustic cell separator. Perfusion at the low temperature resulted in a 3.5-fold increase in specific productivity and a 7-fold increase in volumetric productivity compared to the batch culture at 37°C. The percentage aggregation of β-IFN was reduced from a maximum of 43% in batch culture to a minimum of 5% toward the end of the perfusion phase. The glycosylation profile of all samples showed predominantly sialylated biantennary fucosylated structures. The extent of sialylation, which is important for bioactivity, was enhanced significantly in the perfusion culture, compared to the batch culture.     

三相鼓泡塔生物反应器培养云芝菌合成漆酶

为了提高云芝菌发酵生产漆酶的效率,提出了一种利用自絮凝菌丝球在三相鼓泡塔生物反应器中重复分批发酵产漆酶的新方法。在优化后的产酶条件下,考察维生素C的添加浓度对漆酶活力的影响,并通过在培养基中添加维生素C进行漆酶多批次培养。研究结果表明,维生素C的添加浓度为1.50mmol/L时,可使漆酶活力提高2.6倍。连续进行了10批培养,每批最大漆酶的活力均在1000 U/mL以上,最高酶活出现在第五批为1919.6 U/mL,总培养时间达25 d。此方法所得漆酶对染料靛蓝具有明显的脱色降解作用,在介体1-羟基苯并三唑（HBT）用量0.10%,漆酶用量100 U/L条件下作用40 min时,靛蓝脱色率达到96.7%。该方法采用的三相鼓泡塔生物反应器性能稳定、菌丝球可重复使用,该方法有利于漆酶的高效、规模化生产。     

Gaussian process functional regression modeling for batch data

A Gaussian process functional regression model is proposed for the analysis of batch data. Covariance structure and mean structure are considered simultaneously, with the covariance structure modeled by a Gaussian process regression model and the mean structure modeled by a functional regression model. The model allows the inclusion of covariates in both the covariance structure and the mean structure. It models the nonlinear relationship between a functional output variable and a set of functional and nonfunctional covariates. Several applications and simulation studies are reported and show that the method provides very good results for curve fitting and prediction.     

The design of controllers for batch bioreactors

The implementation of control algorithms to batch bioreactors is often complicated by variations in process dynamics that occur during the course of fermentation. Such a wide operating range often renders the performance of fixed gain proportional-integral-differential (PID) controllers unsatisfactory. In this work, detailed studies on the control of batch fermentations are per formed. Two simple controller designs are presented with the intent to compensate for changing process dynamics. One design incorporates the concepts of static feedforward-feedback control. While this technique produces tighter control than feedback alone, it is not as successful as a controller based on gain scheduling. The gain-scheduling controller, a subclass of adaptive controllers, uses the oxygen uptake rate as an auxiliary variable to fine-tune the PID controller parameters. The control of oxygen tension in the bioreactor is used as a vehicle to convey the proposed ideas, analyses, and results. Simulation experiments indicate significant improvement in controller performance can be achieved by both of the proposed approaches even in the presence of measurement noise.     

Is there a justification for differential a priori weighting in coding sequences? A case study from rbcL and Apocynaceae s.l

Functional constraints are often assumed to influence the performance of nucleotide characters in phylogenetic analysis: First and second codon positions and sites of structural importance are considered to show less homoplasy. We investigate the performance of rbcL characters with differential functional constraints in a cladistic analysis of the plant family Apocynaceae s.l. (Sennblad and Bremer, in prep.). Performance is measured as rescaled consistency indices (rc). We show there is no significant difference in performance between parsimony-informative sites constrained by function in the enzyme, and sites that are not. Furthermore, the substitutions in third-codon position performed significantly better than those in first and second. The variation of rc within the different classes was high, however. Consequently, there is no support for routinely applied a priori differential weighting, neither of codon positions, nor of different functional classes from the present analysis of rbcL data in the Apocynaceae s.l.     

Use of dynamic step response for control of fed-batch conversion of lignocellulosic hydrolyzates to ethanol

Optimization of fed-batch conversion of lignocellulosic hydrolyzates by the yeast Saccharomyces cerevisiae was studied. The feed rate was controlled using a step response strategy, in which the carbon dioxide evolution rate was used as input variable. The performance of the control strategy was examined using both an untreated and a detoxified dilute acid hydrolyzate, and the performance was compared to that obtained with a synthetic medium. In batch cultivation of the untreated hydrolyzate, only 23% of the hexose sugars were assimilated. However, by using the feed-back controlled fed-batch technique, it was possible to obtain complete conversion of the hexose sugars. Furthermore, the maximal specific ethanol productivity (q(E,max)) increased more than 10-fold, from 0.06 to 0.70 g g(-1) h(-1). In addition, the viability of the yeast cells decreased by more than 99% in batch cultivation, whereas a viability of more than 40% could be maintained during fed-batch cultivation. In contrast to untreated hydrolyzate, it was possible to convert the sugars in the detoxified hydrolyzate also in batch cultivation. However, a 50% higher specific ethanol productivity was obtained using fed-batch cultivation. During batch cultivation of both untreated and detoxified hydrolyzate a gradual decrease in specific ethanol productivity was observed. This decrease could largely be avoided in fed-batch cultivations.     

Of "mice" and mammals: utilizing classical inbred mice to study the genetic architecture of function and performance in mammals

The house mouse is one of the most successful mammals and the premier research animal in mammalian biology. The classical inbred strains of house mice have been artificially modified to facilitate identification of the genetic factors underlying phenotypic variation among these strains. Despite their widespread use in basic and biomedical research, functional and evolutionary morphologists have not taken full advantage of inbred mice as a model for studying the genetic architecture of form, function, and performance in mammals. We illustrate the potential of inbred mice as a model for mammalian functional morphology by examining the genetic architecture of maximum jaw-opening performance, or maximum gape, across 21 classical inbred strains. We find that variation in maximum gape among these strains is heritable, providing the first evidence of a genetic contribution to maximum jaw-opening performance in mammals. Maximum gape exhibits a significant genetic correlation with body size across strains, raising the possibility that evolutionary increases in size frequently resulted in correlated increases in maximum gape (within the constraints of existing craniofacial form) during mammalian evolution. Several craniofacial features that influence maximum gape share significant phenotypic and genetic correlations with jaw-opening ability across these inbred strains. The significant genetic correlations indicate the potential for coordinated evolution of craniofacial form and jaw-opening performance, as hypothesized in several comparative analyses of mammals linking skull form to variation in jaw-opening ability. Functional studies of mammalian locomotion and feeding have only rarely examined the genetic basis of functional and performance traits. The classical inbred strains of house mice offer a powerful tool for exploring this genetic architecture and furthering our understanding of how form, function, and performance have evolved in mammals.     

Adaptive pole placement control algorithm for DO-control in beta-lactamase production

The dissolved oxygen (DO) is an important variable in aerobic fermentations and affects the cell growth and product formation. Dissolved oxygen control is difficult in batch fermentations because of the time-varying conditions, time delays, and the probe dynamics. Modeling of the various patterns of biological activity in fermentations and their impact on the DO process dynamics is essential to both achieve a satisfactory control and to track the aforementioned patterns. An adaptive pole placement algorithm with time-delay compensation was used for controlling the DO, coupled with system identification using recursively estimated autoregressive models with exogeneous inputs (ARX). The flow rate of O2 in a constant flow rate gas inlet mixture is used as the manipulated variable. Supervision and coordination techniques are applied to improve the control performance. The control performance is affected by the accuracy of the model prediction and the selected time delay. The effect of DO level on the productivity of beta-lactamase using Bacillus subtilis under oxygen-limited conditions is investigated. Beta-lactamase stability is improved under prolonged growth conditions with low DO levels.     

Model-based optimization of a sequencing batch reactor for biological nitrogen removal

An optimal operating mode for a sequencing batch reactor was determined via a model-based optimization. Synthetic wastewater containing mainly organic matter (as glucose) and nitrogen (as ammonium chloride) was treated without any addition of an external carbon source to accomplish denitrification step. A simplified model was used to describe process dynamics, comprised of six ordinary differential equations and an empirical correlation for oxygen consumption rate. Batch cycle time was the chosen objective function to be minimized for a fixed volume of waste to be treated. Furthermore, as SBR operation is divided in two major phases - aerobic and anoxic, to achieve total pollutants removal within minimum time, these phases can be repeatedly alternated. To ensure availability of organic matter necessary for denitrification, these two phases were combined with feed steps. Different feed strategies were tested using one, two or three feed steps. A successive quadratic programming algorithm was used, and maximum values for final COD, nitrate and ammonium concentrations, as well as maximum feed pump flow rate were some the process constraints. One step feed strategy was indicated by the optimization leading to a batch cycle time of 5h.     

双碳源单细胞蛋白高密度培养

单细胞蛋白(SCP)培养具有增殖速度快、原料来源广、蛋白质含量高等优点,正在成为重要的蛋白质来源之一。生产SCP的原料包括烷烃、低碳醇类及碳水化合物。由碳水化合物,尤其是由各种农副产品加工的废料、造纸工业废水及木质纤维素水解产物等,生产SCP属于废弃资源的综合利用,具有重要的经济和社会意义。这类原料中常含有多种碳源,例如,在木质纤维水解液中,有以木糖为主的五碳糖,也有以葡萄糖为主的六碳糖,木糖与葡萄糖之比约为1:2。这样,木糖的利用就成了一个关键问题。葡萄糖对木糖代谢的抑制作用随葡萄糖比例的降低而减轻;Slinger和Bothast研究了用混合糖培养Candida shehetane的过程,当木糖与葡萄糖的比例为3:1及1:1时,葡萄糖的利用速度分别比木糖高1.6倍及3.4倍;在低还原势时,酵母产酒精速率降低而细胞增长速率加快,可以达到较高细胞浓度。