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Processes
Special Issues
Sustainable Innovation in the Production of Green Materials for Advanced...
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Sustainable Innovation in the Production of Green Materials for Advanced Technologies

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Materials Processes".

Deadline for manuscript submissions: 15 September 2025 | Viewed by 7519

Special Issue Editors

Dr. Navid Aslfattahi

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Guest Editor
Institute of Fluid Dynamics and Thermodynamics, Faculty of Mechanical Engineering, Czech Technical University in Prague, Technická 4, 166 07 Prague, Czech Republic
Interests: nanocomposites; nanofluids; MXene; solar energy; energy storage systems; renewable energy; advanced nanomaterials; energy efficiency; heat transfer
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Kumaran Kadirgama

E-Mail Website
Guest Editor
Faculty of Mechanical and Automotive Engineering Technology, Universiti Malaysia Pahang, Pekan 26600, Pahang, Malaysia
Interests: nanofluids; heat transfer; advanced nanomaterials; energy storage systems; thermal engineering; energy efficiency
Special Issues, Collections and Topics in MDPI journals
Dr. Lingenthiran Samylingam

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Guest Editor
Centre for Advanced Mechanical and Green Technology, Faculty of Engineering and Technology, Multimedia University, Jalan Ayer Keroh Lama, Bukit Beruang, Melaka 75450, Malaysia
Interests: nanofluids; machining; heat transfer fluids; nanomaterials; MXene
Dr. Mohammad Reza Chalak Qazani

E-Mail Website
Guest Editor
Faculty of Computing and Information Technology (FoCIT), Sohar University, Sohar 311, Oman
Interests: motion cueing; manipulator; AI in manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Exploring green materials for the development of advanced technologies to improvise the eco-system situation has attracted significant interest from eminent researchers and industrial communities to proceed with new scientific/practical approaches. Green materials technology has prevailed the scientific community to address the influential environmental problems by producing less pollution in the environment. The development of new green materials with considerations of sustainable innovations is one the most important efforts to establish an environmentally friendly concept. Main factors such as synthesis techniques, fabrication, optimization process, performance evaluation, and reliability will play vital roles in the development of green materials for better performance in advanced technologies to reach the global society goal to enhance the existent eco-system situation, followed by the optimal utilization of renewable resources in advanced production processes. As climate change intensifies around the world and the environmental concerns increase rapidly, it is utterly urgent for the scientific community to understand and utilize the principles of sustainable innovations in green materials production and apply the gained knowledge in this regard towards advanced technologies. Green materials are designed to be either reusable, recyclable, or compostable, or even all three. Waste reduction, smart growth and sustainable development, energy efficiency, and renewable energy are some of the beneficial aspects associated with the development of green materials and their integration into advanced technologies. This Special Issue will cover both experimental and theoretical studies. In this Special Issue, original research articles and reviews are welcome.

We look forward to receiving your contributions. 

Dr. Navid Aslfattahi
Prof. Dr. Kumaran Kadirgama
Dr. Lingenthiran Samylingam
Dr. Mohammad Reza Chalak Qazani
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • green materials
  • sustainable innovation
  • advanced technologies
  • energy efficiency
  • renewable energy
  • eco-friendly systems
  • cleaner production
  • balance in energy production
  • socio-ecological sustainability

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Published Papers (8 papers)

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Research

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14 pages, 1900 KiB  
Article
The Preparation of Experimental Resin-Based Dental Composites Using Different Mixing Methods for the Filler and Matrix
by Maja Zalega, Michał Krasowski, Olga Dawicka, Aleksandra Jasińska, Aleksandra Żabecka, Patrycja Kałuża and Kinga Bociong
Processes 2025, 13(5), 1332; https://doi.org/10.3390/pr13051332 - 27 Apr 2025
Viewed by 173
Abstract
Resin-based composites are common and widely used materials in dentistry in direct and indirect applications. Their mechanical properties depend on the composition and homogeneity of the resulting structure. This study aims to optimize the mixing process to obtain the most homogeneous mixture possible, [...] Read more.
Resin-based composites are common and widely used materials in dentistry in direct and indirect applications. Their mechanical properties depend on the composition and homogeneity of the resulting structure. This study aims to optimize the mixing process to obtain the most homogeneous mixture possible, which will allow for the better mechanical properties of the composite. A mixture of bis-GMA/UDMA/HEMA/TEGDMA monomers forming a polymer matrix was filled with silanized silica (45 wt%) using different mixing methods. This study analyzed five manufacturing methods—hand mixing (agate mortar), mixing in a centrifugal Hauschild SpeedMixer, and the hybrid method—combined with the abovementioned methods. The effect of the mixing method on the Vickers hardness (HV), flexural strength (FS), compressive strength (CS), and diametral tensile strength (DTS) of the produced composites was investigated, and the stresses generated during composite polymerization were determined. Mechanically prepared composites have the highest flexural strength and hardness. The lowest shrinkage stress was achieved by the composite, which was prepared partially manually. The results showed that the mixing method affects the morphology of the filler and, hence, the strength properties of the resulting material. Full article
(This article belongs to the Special Issue Sustainable Innovation in the Production of Green Materials for Advanced Technologies)
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37 pages, 1270 KiB  
Article
Generative Artificial Intelligence in Adaptive Social Manufacturing: A Pathway to Achieving Industry 5.0 Sustainability Goals
by Parisa Jourabchi Amirkhizi, Siamak Pedrammehr, Sajjad Pakzad and Ahad Shahhoseini
Processes 2025, 13(4), 1174; https://doi.org/10.3390/pr13041174 - 12 Apr 2025
Viewed by 583
Abstract
As manufacturing transitions from Industry 4.0 to Industry 5.0, a critical challenge emerges in integrating Generative Artificial Intelligence (GAI) into adaptive social manufacturing to achieve sustainability goals. This transition reflects a paradigmatic shift from a technology-centric model focused on automation and efficiency toward [...] Read more.
As manufacturing transitions from Industry 4.0 to Industry 5.0, a critical challenge emerges in integrating Generative Artificial Intelligence (GAI) into adaptive social manufacturing to achieve sustainability goals. This transition reflects a paradigmatic shift from a technology-centric model focused on automation and efficiency toward a more holistic framework that embeds human-centricity and environmental responsibility into industrial systems. Whereas Industry 4.0 emphasizes digital innovation and productivity, Industry 5.0 seeks to align technological advancement with broader ecological and societal objectives. Despite advancements in automation and digitalization, existing frameworks lack a structured approach to leveraging GAI for environmental, social, and economic sustainability. This study explores the transformative role of GAI in adaptive social manufacturing, addressing the gap in the existing frameworks. Employing a multi-method research design, including content analysis, expert-driven validation, and system dynamics modeling, the study identifies nine key sustainability dimensions of Industry 5.0 and maps them to 17 GAI functions. The findings reveal that GAI significantly enhances adaptive social manufacturing by optimizing resource efficiency, promoting inclusivity, and supporting ethical governance. System dynamics analysis highlights the complex interdependencies between GAI-driven functions and sustainability outcomes, underscoring the need to balance technological innovation with human values. The research provides a novel framework for industries seeking to implement GAI in sustainable production systems, bridging theoretical insights with practical applications. Additionally, it offers actionable strategies to address challenges such as workforce adaptation, ethical AI governance, and adoption barriers, ultimately facilitating the transition toward Industry 5.0’s sustainability goals. Full article
(This article belongs to the Special Issue Sustainable Innovation in the Production of Green Materials for Advanced Technologies)
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22 pages, 6177 KiB  
Article
Synthesis and Property Characterization of AM/AMPS/C18DMAAC/NVP Tetrameric Temperature-Sensitive Thickening Copolymer
by Xu Chen, Xiangpeng Zhu, Cheng Gan, Yigang Li and Diren Liu
Processes 2025, 13(3), 922; https://doi.org/10.3390/pr13030922 - 20 Mar 2025
Cited by 1 | Viewed by 291
Abstract
The stability of cement slurries under high-temperature conditions poses a significant engineering challenge in cementing operations. This study explored the development of a novel tetrameric thermosensitive thickening polymer (TTSTC) as a solution to this problem. Aqueous free radical polymerization was employed to synthesize [...] Read more.
The stability of cement slurries under high-temperature conditions poses a significant engineering challenge in cementing operations. This study explored the development of a novel tetrameric thermosensitive thickening polymer (TTSTC) as a solution to this problem. Aqueous free radical polymerization was employed to synthesize the polymer. The base monomers 2-acrylamido-2-methylpropanesulfonic acid (AMPS) and acrylamide (AM) were employed, in conjunction with the long-chain thermosensitive monomers octadecyldimethylallylammonium chloride (C18DMAAC) and N-vinylpyrrolidone (NVP). The optimal synthesis conditions were determined by orthogonal experiments as follows: monomer molar ratio (AM:AMPS:C18DMAAC:NVP) = 15:10:5:5, initiator concentration of 16 wt%, cross-linker concentration of 0.45 wt%, pH 6, and polymerization temperature of 60 °C. The chemical structure of TTSTC was characterized by Fourier transform infrared spectroscopy (FT-IR), proton nuclear magnetic resonance (1H-NMR), gel permeation chromatography, scanning electron microscopy, Zeta potential, and particle size measurement. The results verified the successful synthesis of the target polymer. Its thermal stability, thermosensitive thickening behavior, and salinity resistance were systematically investigated. Furthermore, the impact of TTSTC on the settling stability, rheological characteristics, and compressive strength of cement paste was assessed. The experimental findings demonstrated that TTSTC displayed noteworthy thermosensitive thickening properties at temperatures up to 279 °C, pH values ranging from 11 to 13, and NaCl/CaCl2 concentrations between 0.05 and 0.5 g/L. The optimal performance of TTSTC was observed at mass fractions ranging from 0.6 to 0.8 wt%. When incorporated into the slurry at 0.6–1.0 wt%, TTSTC significantly improved the slurry settling stability, thickening properties, and 28d compressive strength at elevated temperatures compared with the control. When comparing the temperature-sensitive thickening performance of the newly developed treatment agent with that of the commercially available xanthan gum thickener, the results showed that for the cement slurry system containing the new treatment agent at a mass fraction of 0.6%, the reduction in consistency was 30.9% less than that of the cement slurry system with xanthan gum at a mass fraction of 0.6%. These findings indicate that TTSTC has the potential to function as a highly effective additive in cementing operations conducted in extreme environments, thereby enhancing the stability and dependability of such operations. Full article
(This article belongs to the Special Issue Sustainable Innovation in the Production of Green Materials for Advanced Technologies)
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15 pages, 3131 KiB  
Article
Green Synthesis, Characterization, and Optimization of Chitosan Nanoparticles Using Blumea balsamifera Extract
by Johann Dominic A. Villarta, Fernan Joseph C. Paylago, Janne Camille H. Poldo, Jalen Stephen R. Santos, Tricia Anne Marie M. Escordial and Charlimagne M. Montealegre
Processes 2025, 13(3), 804; https://doi.org/10.3390/pr13030804 - 10 Mar 2025
Viewed by 679
Abstract
Chitosan nanoparticles are nontoxic polymers with diverse biomedical applications. Traditional nanoparticle synthesis often involves harmful chemicals or results in reduced desirable properties, sparking interest in green synthesis methods for nanoparticle production. Utilizing plant-based phytochemicals as reducing and capping agents offers advantages like biocompatibility, [...] Read more.
Chitosan nanoparticles are nontoxic polymers with diverse biomedical applications. Traditional nanoparticle synthesis often involves harmful chemicals or results in reduced desirable properties, sparking interest in green synthesis methods for nanoparticle production. Utilizing plant-based phytochemicals as reducing and capping agents offers advantages like biocompatibility, sustainability, and safety. This study explored Blumea balsamifera leaf extract for chitosan nanoparticle (CNP) synthesis. CNPs were synthesized using pH-induced gelation and characterized by DLS and SEM. B. balsamifera extract, prepared using ethanol, achieved a total phenolic content of 19.37 ± 6.35 mg GAE/g dry weight. DLS characterization revealed a broad size distribution, with an average particle diameter of 908.9 ± 93.6 nm and peaks at 11.11 ± 0.97 nm, 164.45 ± 6.13 nm, and 1672.04 ± 338.75 nm. SEM measurements showed spherical particles with a diameter of 56.8–63.0 nm. UV-Vis analysis, with an absorption peak at 286.5 ± 0.5 nm, was used to optimize CNP biosynthesis through a Face-Centered Central Composite Design (FCCCD). Higher concentrations of B. balsamifera extract (0.05 g/mL) and chitosan (19.1 mg/mL) maximized nanoparticle yield with a mass of 100 μg/mL. Antibacterial testing against E. coli demonstrated a minimum inhibitory concentration of 25 μg/mL. B. balsamifera extract effectively synthesized nanochitosan particles, showing potential for antibacterial applications. Full article
(This article belongs to the Special Issue Sustainable Innovation in the Production of Green Materials for Advanced Technologies)
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17 pages, 4248 KiB  
Article
Determination of Basalt Fiber Reinforcement in Kaolin Clay: Experimental and Neural Network-Based Analysis of Liquid Limit, Plastic Limit, and Unconfined Compressive Strength
by Yasemin Aslan Topçuoğlu, Zeynep Bala Duranay, Zülfü Gürocak and Hanifi Güldemir
Processes 2025, 13(2), 377; https://doi.org/10.3390/pr13020377 - 30 Jan 2025
Viewed by 761
Abstract
The use of basalt fibers, which are employed in various fields, such as construction, automotive, chemical, and petrochemical industries, the sports industry, and energy engineering, is also increasingly common in soil reinforcement studies, another application area of geotechnical engineering, alongside their use in [...] Read more.
The use of basalt fibers, which are employed in various fields, such as construction, automotive, chemical, and petrochemical industries, the sports industry, and energy engineering, is also increasingly common in soil reinforcement studies, another application area of geotechnical engineering, alongside their use in concrete. With this growing application, scientific studies on soil reinforcement with basalt fiber have also gained momentum. This study establishes the effects of basalt fiber on the liquid limit, plastic limit, and strength properties of soils, and the relationships among the liquid limit, plastic limit, and unconfined compressive strength of the soil. For this purpose, 12 mm basalt fiber was used as a reinforcement material in kaolin clay at ratios of 1.0%, 1.5%, 2.0%, 2.5%, and 3.0%. The prepared samples were subjected to liquid limit, plastic limit, and unconfined compressive strength tests. As a result of the experimental studies, the fiber ratio that provided the best improvement in the soil properties was determined, and the relationships among the liquid limit, plastic limit, and unconfined compressive strength were established. The experimental results were then used as input data for an artificial intelligence model. The used neural network (NN) was trained to obtain basalt fiber-to-kaolin ratios based on the liquid limit, plastic limit, and unconfined compressive strength. This model enabled the prediction of the fiber ratio that provides the maximum improvement in the liquid limit, plastic limit, and compressive strength without the need for experiments. The NN results were in great agreement with the experimental results, demonstrating that the fiber ratio providing the maximum improvement in the soil properties can be identified using the NN model without requiring experimental studies. Moreover, the performance and reliability of the NN model were evaluated using 5-fold cross-validation and compared with other AI methods. The ANN model demonstrated superior predictive accuracy, achieving the highest correlation coefficient (R = 0.82), outperforming the other models in terms of both accuracy and reliability. Full article
(This article belongs to the Special Issue Sustainable Innovation in the Production of Green Materials for Advanced Technologies)
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21 pages, 9745 KiB  
Article
Mechanical and Tribological Performance of Epoxy Composites Reinforced with YSZ Waste Ceramics for Sustainable Green Engineering Applications
by Talal Alsaeed, Ayedh Eid Alajmi, Jasem Ghanem Alotaibi, Voravich Ganthavee and Belal F. Yousif
Processes 2024, 12(11), 2609; https://doi.org/10.3390/pr12112609 - 20 Nov 2024
Viewed by 1186
Abstract
The growing need for sustainable materials in engineering applications has led to increased interest in the use of waste-derived ceramics as reinforcing fillers in polymer composites. This study investigates the mechanical and tribological performance of epoxy composites reinforced with Yttria-Stabilized Zirconia (YSZ) waste [...] Read more.
The growing need for sustainable materials in engineering applications has led to increased interest in the use of waste-derived ceramics as reinforcing fillers in polymer composites. This study investigates the mechanical and tribological performance of epoxy composites reinforced with Yttria-Stabilized Zirconia (YSZ) waste ceramics, focusing on the effects of varying ceramic content (0–40 wt.%). The results demonstrate that while the tensile strength decreases with increasing ceramic content, the wear resistance and surface hardness improve, particularly at 20 wt.% YSZ. These findings are highly relevant for industries such as automotive, aerospace, and industrial manufacturing, where the demand for eco-friendly, high-performance materials is growing. This work aligns with the journal’s focus on sustainable engineering by offering new insights into the practical application of waste materials in high-performance composite systems. Full article
(This article belongs to the Special Issue Sustainable Innovation in the Production of Green Materials for Advanced Technologies)
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24 pages, 3863 KiB  
Article
Hybrid CNC–MXene Nanolubricant for Tribological Application: Characterization, Prediction, and Optimization of Thermophysical Properties Evaluation
by Sakinah Muhamad Hisham, Norazlianie Sazali, Kumaran Kadirgama, Devarajan Ramasamy, Mohd Kamal Kamarulzaman, Lingenthiran Samylingam, Navid Aslfattahi and Chee Kuang Kok
Processes 2024, 12(10), 2146; https://doi.org/10.3390/pr12102146 - 2 Oct 2024
Viewed by 1019
Abstract
In the present work, hybrid Cellulose Nanocrystal–MXene (CNC–MXene) nanolubricants were prepared via a two-step method and investigated as potential heat-transfer hybrid nanofluids for the first time. CNC–MXene nanolubricants were synthesized via a two-step method by varying the weight percentage of CNC–MXene nanoparticles (ranging [...] Read more.
In the present work, hybrid Cellulose Nanocrystal–MXene (CNC–MXene) nanolubricants were prepared via a two-step method and investigated as potential heat-transfer hybrid nanofluids for the first time. CNC–MXene nanolubricants were synthesized via a two-step method by varying the weight percentage of CNC–MXene nanoparticles (ranging from 0.01 to 0.05 wt%) and characterized using Fourier-Transform Infrared Spectroscopy and TGA (Thermogravimetric Analysis). Response surface methodology (RSM) was used in conjunction with the miscellaneous design model to identify prediction models for the thermophysical properties of the hybrid CNC–MXene nanolubricant. Minitab 18 statistical analysis software and Response Surface Methodology (RSM) based on Central Composite Design (CCD) were utilized to generate an empirical mathematical model investigating the effect of concentration and temperature. The analysis of variance (ANOVA) results indicated significant contributions from the type of nanolubricant (p < 0.001) and the quadratic effect of temperature (p < 0.001), highlighting non-linear interactions that affect viscosity and thermal conductivity. The findings showed that the predicted values closely matched the experimental results, with a percentage of absolute error below 9%, confirming the reliability of the optimization models. Additionally, the models could predict more than 85% of the nanolubricant output variations, indicating high model accuracy. The optimization analysis identified optimal conditions for maximizing both dynamic viscosity and thermal conductivity. The predicted optimal values (17.0685 for dynamic viscosity and 0.3317 for thermal conductivity) were achieved at 30 °C and a 0.01% concentration, with a composite desirability of 1. The findings of the percentage of absolute error (POAE) reveal that the model can precisely predict the optimum experimental parameters. This study contributes to the growing field of advanced nanolubricants by providing insights into the synergistic effects of CNC and MXene in enhancing thermophysical properties. The developed models and optimization techniques offer valuable tools for tailoring nanolubricant formulations to specific tribological applications, potentially leading to improved efficiency and durability in various industrial settings. Full article
(This article belongs to the Special Issue Sustainable Innovation in the Production of Green Materials for Advanced Technologies)
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Review

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49 pages, 7682 KiB  
Review
Advances in Palladium-Based Membrane Research: High-Throughput Techniques and Machine Learning Perspectives
by Eric Kolor, Muhammad Usman, Sasipa Boonyubol, Koichi Mikami and Jeffrey S. Cross
Processes 2024, 12(12), 2855; https://doi.org/10.3390/pr12122855 - 12 Dec 2024
Cited by 1 | Viewed by 2122
Abstract
The separation of high-purity hydrogen from mixed gasses using dense metallic alloy membranes is essential for advancing a hydrogen-based economy. Palladium-based membranes exhibit outstanding catalytic activity and theoretically infinite hydrogen selectivity, but their high cost and limited performance in contaminant-rich environments restrict their [...] Read more.
The separation of high-purity hydrogen from mixed gasses using dense metallic alloy membranes is essential for advancing a hydrogen-based economy. Palladium-based membranes exhibit outstanding catalytic activity and theoretically infinite hydrogen selectivity, but their high cost and limited performance in contaminant-rich environments restrict their widespread use. This study addresses these limitations by exploring strategies to develop cost-effective, high-performance alternatives. Key challenges include the vast compositional design space, lack of systematic design principles, and the slow pace of traditional material development. This review emphasizes the potential of high-throughput and combinatorial techniques, such as composition-spread alloy films and the statistical design of experiments (DoE), combined with machine learning and materials informatics, to accelerate the discovery, optimization, and characterization of palladium-based membranes. These approaches reduce development time and costs while improving efficiency. Focusing on critical properties such as surface catalytic activity, resistance to chemical and physical stresses, and the incorporation of low-cost base metals, this study introduces domain-specific descriptors to address data scarcity and improve material screening. By integrating computational and experimental methods, future research can identify hidden material correlations and expedite the rational design of next-generation hydrogen separation membranes. Full article
(This article belongs to the Special Issue Sustainable Innovation in the Production of Green Materials for Advanced Technologies)
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