I do not know enough about your system to provide an all-encompassing answer. But here are a few possible approaches to determining the standard deviation of the system when running at steady state:
What is the response that you are measuring? Have you evaluated that measurement process? If so, the reproducibility (or possibly repeatability) of the measurement system is a good guide for estimating the standard deviation of the system. This would likely offer the lowest possible standard deviation.
If this is a production process, running the process with absolutely no changes will often yield the standard deviation of the system.
You could make a formulation, divide it into multiple test specimens and measure each one independently to determine the standard deviation of the system. Note that this removes the variability caused by the actual making of the formulation. If that variability might be large, you may want to create several of the same formulation and measure each one.
One of the key things to consider before running any designed experiment is to perform an evaluation of the measurement system. This would avoid potential problems caused by the measurement system itself. Plus, evaluating that measurement system would provide you with a reasonable idea of the error that you would expect to see from the designed experiment. Thus, it would allow for an appropriate assessment of power for the design given a certain number of runs before you ever perform the experiment. In short, it could help you avoid some of the potential issues/questions about the analysis once the experiment has been conducted.
Dan Obermiller