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The Profitability Impact of a Qualified and Trained Analytical Lab Staff

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The Profitability Impact of a Qualified and Trained Analytical Lab Staff

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    1. The Profitability Impact of a Qualified and Trained Analytical Lab Staff Sabrina Trupia, Ph.D. and Jessica M. Sido NCERC

    2. Three functions of Ethanol Plant Laboratory Staff

    3. Laboratory Performance Time spent on each test decreases Fewer samples to re-run Reliable analyses and reliable data

    5. Understanding Processes Ability to recognize a problem Ability to assess the problem Ability to troubleshoot and to see where the problem originates (plant or lab)

    6. Communication with Plant Conveying the appropriate information to the operators Quick response to changes in plant conditions Providing more information that just data values

    7. Is data integrity and quality (i.e. “good” data) only important to R&D labs?

    8. RFA Guidelines “First, the [QA/QC] program should continually monitor the reliability (accuracy and precision) of the results being reported. It should answer the question “How good (accurate and precise) are the results obtained?” This function is the determination of quality. “ “The second function is the control of quality to meet the program requirements for reliability. “

    9. Is “good” data only important to R&D labs? “Providing the highest quality products that meet customer expectations is of the highest priority for ethanol production facilities” “The success of an ethanol production facility depends on the Quality Control lab” --Kristy Moore, Renewable Fuels Association “Hard to justify [financially] only until you see the results” “When lab data is used as a problem-solving tool, it does save money for the ethanol plant” -- Andrew Kim, Center Ethanol

    10. Laboratory Practices = Problem-solving Tools Fermentation Management Maximize ethanol production Minimize fermentation problems Mass Balance Helps update the mass balance of production Recognize trends leading to problems Risk Management Contaminants (S, antibiotics...) in ethanol and/or co-products

    11. Cost Impact Example: Fermentation Management A single contamination event resulting in one stuck fermentor (3-4% residual sugars) costs approximately $20,000 Chronic contamination resulting in a loss of 0.25%wv ethanol per fermentor = approx. $1,740,000 per year (@ $1.74 per gallon ethanol)

    12. Effective Training Training is best accomplished in three stages Initial : exposure to lab procedures Intermediate : active demonstration Final : Hands-on training Throughout, lab practices are tied to plant processes

    13. Thanks to… Lab Staff @ NCERC John Caupert Brian Wrenn Yan Zhang Jack Ballinger Andrew Kim Kristy Moore …Questions?

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