Elliot Woolley

Simulation of energy consumption in the manufacture of a product

Energy rationalisation, the elimination of unnecessary energy consumption, is becoming increasingly important in a resource constrained world. The use of energy is a significant contributor to greenhouse gas emissions and much research has been done to reduce energy use in manufacturing. So as to enable the rationalisation of energy consumption, it is essential that it is understood where energy is being used. This paper describes the design and implementation of a simulation model that has been generated to support the modelling of energy consumption within manufacturing systems. The simulation model allows various ‘what-if’ scenarios to be investigated thereby enabling engineers to understand the impact of various manufacturing parameters on energy consumption and thus reduce reliance on energy and the production of greenhouse gas emissions.

A Methodology for Sustainable Management of Food Waste

As much as one-third of the food intentionally grown for human consumption is never consumed and is therefore wasted, with significant environmental, social and economic ramifications. An increasing number of publications in this area currently consider different aspects of this critical issue, and generally focus on proactive approaches to reduce food waste, or reactive solutions for more efficient waste management. In this context, this paper takes a holistic approach with the aim of achieving a better understanding of the different types of food waste, and using this knowledge to support informed decisions for more sustainable management of food waste. With this aim, existing food waste categorizations are reviewed and their usefulness are analysed. A systematic methodology to identify types of food waste through a nine-stage categorization is used in conjunction with a version of the waste hierarchy applied to food products. For each type of food waste characterized, a set of waste management alternatives are suggested in order to minimize environmental impacts and maximize social and economic benefits. This decision-support process is demonstrated for two case studies from the UK food manufacturing sector. As a result, types of food waste which could be managed in a more sustainable manner are identified and recommendations are given. The applicability of the categorisation process for industrial food waste management is discussed.

How to manufacture a sustainable future for 9 billion people in 2050

There is a growing body of evidence which increasingly points to serious and irreversible ecological consequences if current unsustainable manufacturing practices and consumption patterns continue. Recent years have seen a rising awareness leading to the generation of both national and international regulations, resulting in modest improvements in manufacturing practices. These incremental changes however are not making the necessary progress towards eliminating or even reversing the environmental impacts of global industry. Therefore, a fundamental research question is: ’How can we meet the long term demand of our growing global population, and in this context, what are the key challenges for the future of manufacturing industry?’ A common approach adopted in such cases is to utilise foresighting exercises to develop a number of alternative future scenarios to aid with long-term strategic planning. This paper presents the results of one such study to create a set of ’SMART Manufacturing Scenarios’ for 2050.

Laser annealing of thin film CdTe solar cells using a 808 nm diode laser

We report on the effect of a new laser annealing treatment for thin film CdTe solar cells using a 808 nm diode laser. As-deposited, laser annealed and MgCl2 treated/laser annealed CdTe thin films have been analysed. One part of the work has been focused on understanding the efficacy of the activation treatment by laser annealing. The results show partial chlorine diffusion and associated partial re-crystallisation of the absorber. The second part of this work has been focused on the effect of the treatment on the chemical composition of the CdTe surface. It has been found that the process also contributes to the formation of a Te-rich layer on the surface of the CdTe absorber, which may provide a useful process to produce a back contact. This paper reveals the effect of the laser treatment on the microstructural properties of the CdTe absorber material. The microstructure has been analysed using STEM/EDX, HRTEM and XRD. Further work is required to optimise the process but it has the potential to provide much greater control than current activation methods and also to provide a Te back contact suitable for CdTe solar cells.

The changing landscape of energy management in manufacturing

The production and use of energy accounts for around 60% of global greenhouse gas (GHG) emissions, providing an intrinsic link between cause and effect. Considering that the manufacturing industry is responsible for roughly one-third of the global energy demand enforces the need to ensure that the manufacturing sector continually strives to reduce its reliance on energy and thus minimise GHG released into the atmosphere. Consequently, efficient management of energy consumption is of paramount importance for modern manufacturing businesses due to well-documented negative impact regarding energy generation from fossil fuels and rapidly rising worldwide energy costs. This has resulted in a proliferation of research in this area which has considered improvements in energy consuming activities at the enterprise, facility, cell, machine and turret levels. However, there is now a need to go beyond incremental energy efficiency improvements and take more radical approaches to reduce energy consumption. It is argued that the largest energy reduction improvements can be achieved through better design of production systems or by adopting new business strategies that reduce the reliance of manufacturing businesses on resource consumption. This chapter initially provides a review of research in energy management (EM) at various manufacturing focus levels. The inappropriateness of current methods to cater for transformative and radical energy reduction approaches is discussed. In particular, limitations are found at the business strategy level since no technique exists to consider the input of these high level decisions on energy consumption. The main part of the chapter identifies areas of further opportunity in energy management research, and describes a method to facilitate further reductions in energy use and GHG production in manufacturing at the business strategy level.

Towards integrating production and consumption to reduce consumer food waste in developed countries

Abstract Literature analysing reasons for Consumer Food Waste (CFW) revealed that it cannot be reduced to consumer behaviour alone. In fact, CFW should not be conceptualised as the problem but as a symptom of a food system that oversupplies and encourages consumerism. This research focuses on preventing CFW in the United Kingdom (UK), as a representative of a developed country, by improving the traditional food provisioning system to better integrate production and consumption. To achieve this, five stages are identified to design a sustainable product service system (PSS) capable of supporting consumers to better manage their food operations: (1) strategic analysis of current food provisioning system, (2) exploring system level innovations leading to minimisation of CFW, (3) refinement and selection of PSS, (4) designing the most promising PSS from an environmental, economic and social perspective, and (5) evaluating designed PSS. This paper considers the first of these stages, reviews reasons for and existing solutions to CFW, and provides a strategic analysis of the current food provisioning system to identify characteristics that could be exploited within a new PSS. Initial investigations reveal applicability of PSS concept to the food provisioning system and potential for reduction of CFW if core causes are addressed.

Forging New Frontiers in Sustainable Food Manufacturing

One of the most prominent challenges commonly acknowledged by modern manufacturing industries is “how to produce more with fewer resources?” Nowhere is this more true than in the food sector due to the recent concerns regarding the long-term availability and security of food products. The unique attributes of food products such as the need for fresh perishable ingredients, health risks associated with inappropriate production environment, stringent storage and distributions requirements together with relatively short post-production shelf-life makes their preparation, production and supply considerably different to other manufactured goods. Furthermore, the impacts of climate change on our ability to produce food, the rapidly increasing global population, as well as changes in demand and dietary behaviours both within developed and developing countries urgently demands a need to change the way we grow, manufacture and consume our food products. This paper discusses a number of key research challenges facing modern food manufacturers, including improved productivity using fewer resources, valorisation of food waste, improving the resilience of food supply chains, localisation of food production, and utilisation of new sustainable sources of nutrition for provision of customised food products.

Complex beam profiles for laser annealing of thin-film CdTe photovoltaics

Within the family of thin-film photovoltaics (PV), cadmium telluride has the fastest growing market share due to its high efficiencies and low cost. However, as with other PV technologies, the energy required to manufacture the panels is excessive, encompassing high environmental impact and manufacturing energy payback times of the order of 2–3 years. As part of the manufacturing process, the panels are annealed at temperatures of approximately 400 °C for 30 min, which is inherently inefficient. Laser heating has previously been investigated as an alternative process for thin-film annealing, due to its advantages with regard to its ability to localize heat treatment, anneal selectively, and its short processing time. In this investigation, results focusing on improvements to the laser-based annealing process, designed to mitigate panel damage by excessive thermal gradients, are presented. Simulations of various laser beam profiles are created in comsol and used to demonstrate the benefit of laser beam shaping for thin-film annealing processes. An enabling technology for this, the holographic optical element, is then used to experimentally demonstrate the redistribution of laser beam energy into an optimal profile for annealing, eliminating thermal concentrations.Within the family of thin-film photovoltaics (PV), cadmium telluride has the fastest growing market share due to its high efficiencies and low cost. However, as with other PV technologies, the energy required to manufacture the panels is excessive, encompassing high environmental impact and manufacturing energy payback times of the order of 2–3 years. As part of the manufacturing process, the panels are annealed at temperatures of approximately 400 °C for 30 min, which is inherently inefficient. Laser heating has previously been investigated as an alternative process for thin-film annealing, due to its advantages with regard to its ability to localize heat treatment, anneal selectively, and its short processing time. In this investigation, results focusing on improvements to the laser-based annealing process, designed to mitigate panel damage by excessive thermal gradients, are presented. Simulations of var...

Eco-Intelligent Factories: Timescales for Environmental Decision Support

Manufacturing decisions are currently made based on considerations of cost, time and quality. However there is increasing pressure to also routinely incorporate environmental considerations into the decision making processes. Despite the existence of a number of tools for environmental analysis of manufacturing activities, there does not appear to be a structured approach for generating relevant environmental information that can be fed into manufacturing decision making. This research proposes an overarching structure that leads to three approaches, pertaining to different timescales that enable the generation of environmental information, suitable for consideration during decision making. The approaches are demonstrated through three industrial case studies.

A manufacturing approach to reducing consumer food waste

Globally, one third of food produced is wasted. In the UK, 47% of the food waste is post-consumer revealing a need to encourage more efficient consumption. This research asserts that manufacturers and retailers can play a crucial role in minimising consumer food waste (CFW) through consumer engagement and provision of smart solutions that ensure more efficient use of food products. Supporting manufacturers and retailers to minimise CFW can be achieved via two stages: a) understanding and evaluating CFW, and b) identifying improvements to manufacturing and retail activities that would reduce CFW. On-site waste audits have identified that the percentage of edible CFW from domestic environments (77%) is greater than that disposed of in public areas (14%) supporting the hypothesis that improving the full food provisioning process (e.g. packaging, storage, guidance) would be beneficial. This paper proposes a number of mechanisms to support manufacturing and retail in reducing CFW.