Browsing by Author "Salah, Sameh A"

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INTEGRATION OF ENERGY SAVING WITH LEAN PRODUCTION IN A FOOD PROCESSING COMPANY
(Editorial Institution of Wrocaw Board of Scientific, 2021-12-08) Salah, Sameh A; Mustafa, Ahmad
Increasing the energy efficiency has become a key concern in manufacturing companies due to the increased energy costs and the environmental impacts. More efficient energy saving can make the most economic contribution towards solving these problems in the short run. Companies’ governments are striving to identify the most effective measures to improve energy efficiency in manufacturing processes. The specific energy consumption (SEC) is a key performance indicator used to measure the energy consumed per product. Therefore, an improvement of this value contributes to decouple of economic growth from related increase of energy consumption. This paper highlights the needs of manufacturing companies for integrating energy performance in production management. This work focuses on studying the impact of implementing lean production concepts on decreasing the SEC in a food processing organization. The reduction of SEC can be achieved by increasing the total efficiency of the production line. Implementing the lean production methodology by using energy management model achieve an increase in the production output. The lean production used to eliminate all kinds of waste in production, while using the same input resources such as raw material and energy. The main source of waste found on the production line is the defective product and time waste during changeover and manual process. The achieved results showed that the SEC improved by 15.1% by reducing the lean wastes in the production line. Implementation of lean methodology has a great impact on improving the energy saving by reducing the specific energy consumption in the organization. The SEC is a key performance indicator used to measure the efficiency of a production line or a machine in relation to its production. Energy management model is useful in identifying the area of improvement and the energy saving measure. © 2021, Editorial Institution of Wrocaw Board of Scientific. All rights reserved.
Selective synthesis of alpha monoglycerides by a clean method: Techno-economic and environmental assessment
(Elsevier, 2022-04-12) Mustafa, Ahmad; Niikura, Fumiya; Pastore, Carlo; Allam, Hoda A; Hassan, Omnia Bassam; Mustafa, Muhamad; Inayat, Abrar; Salah, Sameh A; Abdel Salam, Ahmed; Mohsen, Reham
This work proposes an alternative green and selective biocatalytic route for Glycerin Mono- stearate (α-monostearin) production. The conventional method of production uses an elevated temperature. Apart from the high energy consumption, such high temperatures darken the final product’s color, lead to random reactions, and produce high orders of diglycerides and tri- glycerides instead of monoglycerides. The proposed production process was performed by esterifying stearic acid with glycerin in an organic medium using Candida antarctica lipase (Novozym 435) at a mild temperature. The reaction conditions were optimized using the response surface methodology (RSM): optimum conditions were a temperature of 60 ◦C, glycerin to stearic acid molar ratio of 8:1, and Novozym 435 amount of 6% w/w. The solvent addition remarkably improved the α-monostearin yield to nearly 80% without the need for the energy-intensive distillation step. The conventional autocatalytic esterification (AUT) process was also per- formed to investigate the comparative monoglyceride yield, and it was found to be 22.5%. Proton nuclear magnetic resonance and gas-chromatography confirmed that α-monostearin could be produced with the highest purity using the proposed enzymatic method (ENZ). Economic and environmental analyses were also conducted for the proposed ENZ process, and the results were compared with those of the AUT process. The total capital investment of α-monostearin pro- duction, considering a projected capacity of 4950 t year− 1 and 11% interest for the proposed ENZ process, was favorably 2.5 times lower than that of the AUT process, suggesting a promising investment opportunity. However, the total production costs showed unfavorable negative net present value (NPV) and return on investment (ROI) for the ENZ process and favorable positive NPV and ROI for the AUT process, indicating that the proposed venture is not profitable for α-monostearin production. However, the process can be profitable at improved operational sta- bility of Novozym 435 up to 1 kg per 3-ton product. The carbon footprint was calculated on the basis of the given capacity and conditions of 50 and 656 t CO2 eq./year for the ENZ and AUT processes, respectively. The synthesis of α-monostearin using the proposed route can be consid- ered a building block toward a cleaner large-scale production of α-monoglycerides.