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Innovations in Manufacturing Processes and Systems for Sustainable Practices (2nd Edition)

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

Deadline for manuscript submissions: 31 August 2026 | Viewed by 8220

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Special Issue Editors

Dr. Raul D. S. G. Campilho

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Guest Editor

Department of Mechanical Engineering, ISEP-School of Engineering, Polytechnic of Porto, R. Dr. António Bernardino de Almeida, 431, 4200-072 Porto, Portugal
Interests: composite materials; joining processes; automation
Special Issues, Collections and Topics in MDPI journals

Dr. Flávia Barbosa

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Guest Editor

Institute of Science and Innovation in Mechanical and Industrial Engineering, 4200-465 Porto, Portugal
Interests: green manufacturing; sustainable and circular product design; human-centric design; technology acceptance

Special Issue Information

Dear Colleagues,

Manufacturing has been a fundamental driver of industrial and economic development, continually adapting to technological advancements and increasing global concerns regarding sustainability. The chemical, biological, materials, energy, food, and pharmaceutical industries, in particular, face growing pressure to optimize manufacturing processes and systems to meet high standards of efficiency, precision, and environmental responsibility. This Special Issue aims to explore the latest innovations in manufacturing processes and systems within these critical sectors, with an emphasis on sustainable and energy-efficient practices. The focus is on novel advancements in automation, robotics, additive manufacturing (3D printing), digitalization, and data-driven optimization that enhance production capabilities while minimizing waste and resource consumption. Contributions that explore new methodologies for improving process sustainability, reducing emissions, and enhancing circular economy principles are especially welcome.

Moreover, the integration of Industry 4.0 concepts, including smart manufacturing, real-time data analytics, and machine learning applications, continues to transform industrial production by implementing adaptive and intelligent manufacturing environments. Additionally, emerging technologies such as bio-based materials, green chemistry, and advanced recycling methods present new approaches for sustainable industrial growth. This Special Issue invites original research articles and comprehensive reviews that provide novel insights into innovative process design, waste reduction, energy conservation, and environmentally friendly manufacturing solutions. The objective is to highlight transformative manufacturing approaches that align with stringent environmental regulations and societal expectations, contributing to the long-term sustainability of industrial production.

Please note that submissions related to management strategies, corporate performance, and economic analysis will not be considered for this Special Issue, as the focus is strictly on manufacturing processes and systems within the aforementioned sectors.

We look forward to your contributions.

Dr. Raul D. S. G. Campilho
Dr. Flávia Barbosa
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 250 words) can be sent to the Editorial Office for assessment.

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 semimonthly 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

manufacturing processes
sustainable manufacturing
process optimization
automation
robotics
green manufac-turing
additive manufacturing (3D printing)
energy-efficient processes
waste reduction
circular economy
chemical manufacturing
biological processes
material processing
pharmaceutical production
food engineering
Industry 4.0
digitalization
smart manufacturing systems
bio-based materials
green chemistry
advanced recycling methods

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Innovations in Manufacturing Processes and Systems for Sustainable Practices in Processes (23 articles)

Published Papers (9 papers)

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Research

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16 pages, 951 KB

Open AccessArticle

Dynamic Innovation Portfolio Management: A Model Predictive Control Approach for Product-Process Innovation Trade-Offs

by Sobhi Mejjaouli and Lotfi Tadj

Processes 2026, 14(3), 557; https://doi.org/10.3390/pr14030557 - 5 Feb 2026

Viewed by 191

Abstract

The proposed model derives closed-form solutions for investment efforts in both product development and its associated production processes while balancing economic profit, product quality, and marginal production costs. The system dynamics, including state and control variables, as well as the relevant constraints, are explicitly formulated. To demonstrate the practical utility of the framework, a numerical example is investigated. Simulation results illustrate adaptive strategies that anticipate future market conditions, manage product–process innovation trade-offs, and respond effectively to changing innovation returns. In the baseline numerical scenario, the model achieves a cumulative profit of 7850 with an average period profit of 196. Finally, a sensitivity analysis is conducted to examine the impact of key model parameters on system performance. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices (2nd Edition))

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19 pages, 6500 KB

Open AccessArticle

Robotic Sequential Ultrasonic Welding of Thermoplastic Composites: From Coupons to a Full-Scale Fuselage Demonstrator

by Abhas Choudhary, Ioan Bîrgăoanu-Acăei and Irene Fernandez Villegas

Processes 2026, 14(3), 528; https://doi.org/10.3390/pr14030528 - 3 Feb 2026

Viewed by 197

Abstract

Sequential ultrasonic spot welding is an interesting joining method for overlapping thermoplastic composite structures. In the framework of the EU Clean Aviation Multi-functional Fuselage Demonstrator (MFFD) and the lower shell SmarT multifunctional and INteGrated TP fuselage (STUNNING) projects, SAM XL and TU Delft Aerospace Engineering collaboratively developed and demonstrated a robot-based sequential ultrasonic spot welding process for the sub-assembly of structural frames and clips in a fuselage section demonstrator. This full-scale thermoplastic composite fuselage section demonstrator, which was recently awarded the 2025 JEC Innovation award, measures 8.0 m in length and 4.0 m in diameter. Our robot-based sequential ultrasonic spot welding technology played an important role in ensuring the joining of structural clips and frames in the stiffened fuselage skin of the demonstrator, through the use of more than 1600 spot welded joints with an average welding time of approximately 10 s per spot, thereby significantly reducing cycle times as compared to traditional joining methods such as fastening or riveting. This paper provides a comprehensive overview of the technology development process and highlights the results achieved during the sub-assembly of the demonstrator, as well as the challenges encountered. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices (2nd Edition))

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19 pages, 7109 KB

Open AccessArticle

Associated LoRaWAN Sensors for Material Tracking and Localization in Manufacturing

by Peter Peniak, Emília Bubeníková and Alžbeta Kanáliková

Processes 2026, 14(1), 175; https://doi.org/10.3390/pr14010175 - 5 Jan 2026

Viewed by 315

Abstract

Material tracking and localization are key applications of Industry 4.0 in manufacturing process control. Traditional approaches—such as barcode or QR code identification and RTLS-based localization using RF/UWB, 5G or GPS–require a large and complex infrastructure. As an alternative, this paper proposes an IoT-based solution that combines short-range Bluetooth Low Energy (BLE) communication with LPWAN LoRaWAN networks. Hybrid solutions using LoRaWAN and BLE technologies already exist, but pure localization based on BLE tags can lead to ambiguous asset identification in geometrically dense scenarios. Our paper aims to solve this problem with an alternative concept called Associated LoRaWAN Sensors (ALSs). An ALS enables logical grouping and integration of heterogeneous LoRaWAN sensors, providing their own data or directly scanning BLE tags. Sensor data can be combined and supplemented with new information, data, and events, supported by application logic (use case). Although ALS represents a general concept that could be applicable to various use cases (such as warehouse monitoring, object tracking), our paper will focus mainly on material tracking and validation in manufacturing. For this purpose, we designed a specific ALS model that integrates a classic LoRaWAN BLE sensor with an additional LoRaWAN magnetic contact sensor. The magnetic contact switch can provide validation of exact position, in addition to localization by BLE tag. Experimental validation using BLE tags (Trax 10229) and LoRaWAN sensors (IoTracker3, Milesight WS301) demonstrates the usability of the ALS model in typical industrial scenarios. We also measured RSSI and evaluated the accuracy of tag localization (3 × 25 = 75 tests) for the worst-case scenario: material validation on a machine with a BLE tag distance of ~0.5 m. While the traditional approach showed up to a 20% failure rate, our ALS model avoided the issue of incorrect accuracy. An additional magnetic switch in ALS confirmed that the correct carrier with the associated tag is attached to the machine and eliminated incorrect localization. The results confirm that a hybrid model based on BLE and LoRaWAN scanning can reliably support material localization and validation without the need for dense RTLS infrastructures. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices (2nd Edition))

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22 pages, 7988 KB

Open AccessArticle

Utilization of Plastic Waste in Concrete Pavement

by Nancy Sakr and Mohamed AbouZeid

Processes 2026, 14(1), 38; https://doi.org/10.3390/pr14010038 - 22 Dec 2025

Viewed by 439

Abstract

The incorporation of utilized plastic waste into concrete mix designs for precast pavement applications presents a highly efficacious strategy, yielding demonstrably superior mechanical properties. High-density polyethylene (HDPE) is the proposed type of plastic in this study. It demonstrates remarkable performance and durability characteristics. The methodology not only significantly curtails landfill waste and incineration but also contributes to a reduction in energy consumption within the concrete sector, thereby establishing itself as a definitive sustainable solution that addresses environmental, economic, and societal imperatives. The optimal incorporation ratio for the recycled plastic within concrete matrices is determined to fall between 10% and 15%, as this range facilitates the attainment of the most desirable material properties. This study specifically focuses on plastic waste and the incorporation of recycled plastic into concrete materials. The emphasis on plastic is due to its material properties, which are particularly well-suited for concrete applications. Experimental tests are conducted on recycled concrete in comparison with the conventional concrete. The results demonstrate high mechanical properties to the recycled concrete. The novelty of this research is the type of plastic used in the concrete mix. Although most of the worldwide applications use Polyethylene Terephthalate (PET), HDPE showed exceeding properties and performance. Two important factors that influence the architectural aspect of construction materials are the heat island effect and the solar reflective index. These factors affect the energy absorption and emissivity rates of construction materials. The embodied carbon in the concrete mix impacts environmental and energy consumption rates, which directly relate to climate change, one of the Sustainable Development Goals (SDGs). Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices (2nd Edition))

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12 pages, 873 KB

Open AccessCommunication

Buffer Recycling in an Integrated Antibody Downstream Process for Improved Sustainability

by Julius Klemens Lorek, Madelène Isaksson and Bernt Nilsson

Processes 2025, 13(11), 3563; https://doi.org/10.3390/pr13113563 - 5 Nov 2025

Viewed by 800

Abstract

The downstream process of monoclonal antibodies (mAbs) is expensive and significantly contributes to overall manufacturing costs. One primary reason is the extensive consumption of water and chemicals required for preparing large volumes of various buffers, essential for multiple chromatography and filtration steps. Reducing the water consumption in biopharmaceutical processes is critical to drive down costs and improve sustainability, which can be achieved through the introduction of buffer recycling. In this study, we implemented buffer recycling in an integrated two-step mAb downstream process consisting of a Protein A capture step in a periodic counter-current (PCC) set-up, followed by a mixed-mode polishing step in flowthrough mode. Buffer recycling was implemented during the cleaning-in-place (CIP) phases of the integrated steps, where the CIP buffer from the polishing column was recovered and reused counter-currently in the CIP phase of the capture column. Compared to the reference process without buffer recycling, this approach resulted in 29% savings in CIP buffer, while maintaining product purity within 0.66% and yield within 1.68% of the reference process. These minor differences confirm that buffer recycling can be implemented without compromising product quality. Through buffer recycling, we see significant potential to improve process sustainability in biomanufacturing by conserving water and reducing chemical waste. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices (2nd Edition))

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18 pages, 1684 KB

Open AccessArticle

Workplace Exposure to Dust Emissions in Additive Manufacturing with an FFF Method

by Adam Hamrol and Filip Osiński

Processes 2025, 13(11), 3470; https://doi.org/10.3390/pr13113470 - 29 Oct 2025

Viewed by 831

Abstract

This article presents the results of research on dust emissions generated by the additive manufacturing process (3D printing) using an FFF method and its impact on the human work environment. The study utilized filaments from three manufacturers in three color variants: neutral, yellow, and black, all made from polylactic acid (PLA), one of the most commonly used polymers in FFF processes. The findings indicated that dust emission levels vary significantly depending on the selection of printing process parameters and the type of filament used. Among the process parameters, the extruder temperature and nozzle diameter have the greatest influence on emission levels. It was shown that at high temperatures and with a small nozzle diameter, the emission level can exceed values hazardous to human health within a short printing time. The maximum recorded Dust Emission Intensity Index (DEII) reached 1058 µg/h when printing with black PLA filament under high-temperature conditions (225 °C, 0.4 mm nozzle). Under these parameters, the predicted dust concentration in a 29 m³ room without ventilation exceeded the WHO limit of 50 µg/m³ for PM₁₀ after approximately 98 min of continuous operation. These results indicate that even desktop-scale FFF printing can pose a measurable risk to indoor air quality when unfavorable process settings are applied. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices (2nd Edition))

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22 pages, 5246 KB

Open AccessArticle

Improving Health and Safety in Welding Through Remote Human–Robot Collaboration

by Shahram Sheikhi, Sharath P. Subadra, Robert Langer, Lucas Christoph Ebel, Eduard Mayer, Patrick Zuther and Jochen Maaß

Processes 2025, 13(9), 3017; https://doi.org/10.3390/pr13093017 - 21 Sep 2025

Viewed by 1420

Abstract

Welding is an essential process across various industries; however, it exposes workers to dangerous fumes, extreme heat and physical stress, which pose considerable health and safety hazards. To tackle these issues, this article introduces the creation of a remote-controlled human–robot welding system aimed at safeguarding workers while ensuring the quality of the welds. The system monitors a welder’s torch movements through a stereoscopic sensor and accurately reproduces them with a robotic arm, facilitating real-time remote welding. Operated by a student, it effectively welded standardized sheet metals in overhead positions while adhering to critical quality standards. The weld geometry met ISO 5817 requirements, tensile strength surpassed the base material specifications, and bending and hardness assessments verified the durability and integrity of the welds. When utilized in hazardous settings, the system showcases its capability to produce high-quality welds while significantly enhancing worker safety, underscoring its potential for real-world industrial applications. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices (2nd Edition))

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25 pages, 6357 KB

Open AccessArticle

Investigation of a Composite Material Painting Method: Assessment of the Mixture Curing of Organic Coatings

by Anca Barbu, Anamaria Ioana Feier, Edward Petzek and Marilena Gheorghe

Processes 2025, 13(8), 2394; https://doi.org/10.3390/pr13082394 - 28 Jul 2025

Cited by 2 | Viewed by 1061

Abstract

The present investigation highlights the importance of evaluating the painting process on a composite material, namely the Kevlar validation process. Kevlar, a synthetic fabric, is well known for its remarkable strength and durability. Kevlar is used in the construction of spaceships and airplanes because it is lightweight and five times stronger than steel. This paper will present the methods for measuring paint layer thickness in accordance with EN ISO 2808:2019, confirming that organic coatings have fully cured, and coating thickness will be measured using magnetic currents. This study will also address the topic of determining liquid resistance. The protocols for manufacturing the Kevlar specimen are in accordance with ISO 2812-2:2018 using the water immersion method and structural testing. The investigation also demonstrates the progress of the framing test following immersion in Airbus PTP metal test tubes. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices (2nd Edition))

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22 pages, 827 KB

Open AccessReview

Integrating Circular Economy Principles in Petroleum Produced Water Management: Toward Sustainable Resource Recovery and Waste Minimization

by Abdelaziz Khlaifat, Sherif Fakher, Fady Hany Ezzat, Mohammad Alalaween and John Galiotos

Processes 2025, 13(11), 3604; https://doi.org/10.3390/pr13113604 - 7 Nov 2025

Viewed by 1943

Abstract

Oil production generates approximately 250 million barrels of produced water (PW) daily, nearly three times the volume of oil, with salinity levels reaching up to 300,000 ppm. Improper management of this wastewater causes significant environmental degradation, including soil salinization and aquatic toxicity. To address these impacts, this study applies circular economy (CE) principles to PW management through flash vaporization and resource recovery. Implementing this approach enables 85–90% water recovery and reduces salinity to below 1000 ppm, allowing reuse for irrigation. Simultaneously, residual brine processed via evaporation ponds yields 15–25% potash (KCl) and 30–40% halite (NaCl), thereby transforming waste into valuable products. As a result, the integrated CE process can reduce wastewater disposal by 80%, cut greenhouse gas emissions by 25–30%, and lower treatment costs by 20–35%, while generating additional revenue of $150–300 per ton of recovered potash. These outcomes demonstrate that adopting CE strategies in PW management not only mitigates environmental degradation but also strengthens economic resilience and resource efficiency. The framework offers a scalable pathway for achieving the UN Sustainable Development Goals (SDG 6 and 12) and advancing sustainability within the oil and gas industry. Full article

(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices (2nd Edition))

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