HLL Kanagala Plant History

KarnataKa Law Society’S

Gogte Institute of Technology

Udyambag , Belgaum.

Department of mechanical engineering
A report on
“ Industrial inplant training ”
At

Kanagala, Belgaum -591225
Training guide : Shri. Badiger A.S
Trainee name : Mr. Shreenath Metri
Training Period : 06 July to 06 Aug 2012

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“Industrial Inplant Training” by Shreenath Metri BE IV Mechanical

Acknowledgement
I consider it my privilege to express my gratitude
and respect to all those who have guided me in this
training.

I thank Mr.Veerendra H. Asst. Manager(HR), HLL
Lifecare Limited, Kanagala –Belgaum for permitting me
to carryout the inplant training in the organization.

I am obliged to Mr. Badiger A.S for giving his
valuable time and constant guidance during the course
of the training.

Finally, I express my gratitude to my parents, friends
and who morally supported and guided me during my
training

---------- ---Thank you one and all--------------

Shreenath Metri

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CONTENTS
Part – A : Company overview
1. Industry Profile
2. Company Profile
3. Objectives of the company
4. History of HLL Kanagala Unit
5. Unit profile
6. Departments
7. Product profile

Part – B : Mechanical Maintenance
1. Mechanical workshop
 Grinding machine (pedestal)
 Broaching machine
 Lathe machine
 Drilling machines (piller & radial )
 Milling machine
 Shaping machine
 Welding machine (electric & Gas
 Hydraulic power press
 Platform scale weighing machine
2. Boiler or steam generators
 Introduction
 Areas of application
 Classification of Boiler
 Difference between fire tube and water tube boilers
 Boiler mountings and accessories

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 Thermax boiler
 Nestler boiler
 Boiler maintenance
3. Effluent Treatment Plant (E.T.P)
 Introduction
 Importance of ETP Plants
 Application of ETP Plants
4. Reverse Osmosis Plant (R.O.P)
 Need
 Features
 Operation
 Advantages
 Applications
5. Air compressors
 Introduction
 Types of air compressor
 Uses of Compressed air
 KHOSLA air compressors model VYDT
 Accessories
 Maintenance
6. Diesel Generators
 Introduction
 Area of application
 Generator size
 General layout of diesel generator
 Maintenance

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Part – C : Production Department
1. Condom plant
 Products of HLL Lifecare Limited
 Primary Production Plant
 Compounding section
 Moulding section
 Vulcanizing section
 Quality Control Department
 ETD (electronic testing dept)
 Packing department
2. Oral Contraceptive Pills (O.C.P)
 Granulation
 Tablet Compression
 Tablet Coating
 Common tablet defects
 Packaging Training
3. Bulk Drug Unit (B.D.U)
 Introduction
 Manufacturing process
 Reactors
 Mechanical Utilities
4. Sanitary Napkin Plant(S.N.P)
 Raw materials required
 Quality control Procedure
 Machine description

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Part - A
(company Overview)

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INDUSTY PROFILE
Hindustan latex’s (HLL) journey started with its incorporation as a
corporate entity under the ministry of health and family welfare of the
government of India on march 1,1966.HLL was setup in the natural rubber rich
state of kerala , for the production of male contraceptive sheaths for the national
family planning programme the company commenced its commercial operations
on April 5,1969. the plant was established in technical collaboration with M/s
Oakmont industries.

To trace briefly HLL’s land mark in the 37th since it’s commencement of
operation. In the year 1969 the company started manufacturing at
thiruvananthpuram (karalla) . As part of expansion program of the company starts
decided to establish One more unit Kanagala near Belgaum in the year 1986. and
they start the manufacturing in 1987.

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COMPANY PROFILE
HLL is today a multi product, multi- unit organization addressing
various public health challenges facing humility. Hindustan life care limited is the
only company in the world which manufactures and markets the widest range of
contraceptives. It is unique in
providing a range of condoms, including female condoms, intra uterine devices,
oral contraceptive pills- steroidal in the area of contraceptives HLL has added to its
oral contraceptive pills(OCP)for female. Its OCP range include Mala D/N, Saheli,
Arpana, Apsara, Menders, Jaljeevan etc, it has also added female condoms to
range. It also started manufacturing of copper T, Blood bags, Hydrocephalus shunt,
Hand gloves etc.
Today HLL is a multi-product, multi-unit organization addressing various
public health challenges facing humanity. On the path of rapid growth, HLL has
set its sights to be a Rs 1000 crore company by the year 2010.

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OBJECTIVES OF THE COMPANY
 To maximize capacity utilization of existing plant.
 To increase the profitability of the company and to maximize generation of
surplus to enable HLL to finance its diversification projects.
 To make social marketing projects.
 To maintain and improve the existing cordial relationship between
employees and management by mutual interaction at various levels and to
further improve efficiency of the executives, supervisors and works to meet
future challenges.
 To make continuous efforts for up gradation of technology and quality to be
internationally competitive.
 To improve substantially direct marketing for all products.
 To maximize cost reduction.
 To explore possibilities for strategic alliances for diversification.
 To be an active player in realization of the objectives set forth in the national
population policy (NPP)2000.
 To straighten information, education and communication aimed at
enhancing the outreach of contraceptives in remote areas

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HISTORY OF HLL KANAGALA UNIT
HLL was set up 1969 at Thiruvananthapurm, Kerala as a government of
India undertaking. In 1984 the company decided to establish one more unit at
Kanagala Belgaum district of Karnataka state.

Shri.R.Venkataraman the vice-president Government of India laid down the
foundation stone for the Kanagala unit. The function was prescribed by Shri.
Shankaranand, the ministry of Health and Family welfare of Government of India.
The construction of plant was completed in 1986 and regular production
commenced from March 1987.
The Kanagala plant is setup in collaboration with M/s Okamoto Industries,
Japan and it incorporates Japanese technology cable of manufacturing tested
condoms in the world. The plant is fully automated andcomputerized and it has
annual production capacity of 144 million condom

Location of the Plant:
The plant is situated in Kanagala, a small village in hukkeri taluka of
Belgaum District. It is 55 kms away from Belagum, 12 kms from
Sankeshwar and 15 kms from Nippani. It is situated beside the NH-4,
which is convenient for transportation and means for communication. In
1984 Shri. B.Shankaranand took the initiative step in the successful
establishment of Kanagala unit of HLL.

HLL unit Kanagala plant acquires of about 30 acres of land. About 3/4th of
land is occupied by administrative office, main factory building,
electrical and maintenance department, boiler room, effluent plant, stores building,
ammonia storages, rest room, time office, canteen and
assistance aid room, locker room etc. Other two buildings have been
constructed one for production of oral contraceptive pills like Mala D,
Mala N, Choice, Saheli, Ecroz etc. And one more is production of
Centchroman Bulk Durg, which has annual production capacity of 1,000
kilograms. Other side of the factory there is a guesthouse, a hostel for
unmarried officers and quarters for General Manger and Deputy General

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manger. The Kanagala plant, Karnataka commenced operation with the production
of condoms in 1985 using Japanese technology. It was expanded with the tablet tin
Facility for birth control pills, Mala D/N, Saheli commenced in 1992.

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UNIT PROFILE:

Name : Kanagala Facility, Belgaum

Address : HLL Lifecare limited

A/P-Kanagala-591225

Tal-Hukkeri

Dist-Belgaum

State-Karnataka.

Corporate : Public Limited Company

Status : A Government of India enterprise

Registration No : KTK/25/11/87

Nature of Industry : Manufacturing.

Date of commencement : March 1987

e-mail : hllnfk@sancharnet.in

Web-site : www.hlllifecarehll.com

Fax No. : 08333-279245

Phone no. : 08333-279244, 279206,279680

Promoter : Late. Shri.B. Shankaranand

Former minister of Health and family

Welfare of Government of India.

CMD : Shri.M.Ayyappan.

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The Kanagala unit is divided into the following

Departments:

Operations and production :
 Boiler house
 Machine shop
 HR
 Accounts
 Purchase
 Stores
 Dispatch
 Systems
 Safety
 Electrical
 Mechanical
 Research and Development

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PRODUCT PROFILE
The various products produced and marketed by the company are as
shown below:

HEALTHCARE PRODUCTS

Blood Single, Double, Triple, Quadruple, Penta, Pediatric, & Transfer Bags.
Sutures Hicon, Hincryl, Hisil, hilon.
Tissues expanders HLL Subcutex
Auto Disposable Syringe Bsure, Autolok
Oral Re-hydration salts Jal Jeevan
Medicated Plasters Plastid
Women Healthcare Pharma Products.

FAMIL PLANNING & HIV/AIDS PREVENTION:
CONDOMS
Nirodh Deluxe Nirodh Mauj
Zaroor Rangeele Nymph
Ustad Share TNMSC
Moods Sparsh Rakshak
Moods Suprereme

Female condoms- Confidom Passion Rings

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Part - B
(Mechanical Maintenance)

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MECHANICAL WORKSHOP
1. Grinding machine (pedestal)

2. Broaching machine

3. Lathe machine

4. Drilling machines (piller & radial )

5. Milling machine

6. Shaping machine

7. Welding machine (electric & Gas)

8. Hydraulic power press

9. Platform scale weighing machine

Grinding machine :
Grinding Machines are also regarded as machine tools. A distinguishing
feature of grinding machines is the rotating abrasive tool. Grinding machine is
employed to obtain high accuracy along with very high class of surface finish on
the workpiece. However, advent of new generation of grinding wheels and
grinding machines, characterised by their rigidity, power and speed enables one to
go for high efficiency deep grinding (often called as abrasive milling) of not only
hardened material but also ductile materials.

Broaching machine :
Broaching is the method of removing metal by pushing or pulling a cutting
tool called a broach when cutted in fixed path.

Broaching machines are probably the simplest of all machine tools. They
consists of work holding fixture, a broaching tool, a drive mechanism, and
supporting frame.

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Specifications of Broaching machine:

Stroke(mm) :

Driving force :

Breaching speed(mpm) :

Return speed(mpm) :

Motor h.p :

Lathe machine :
It is one of the oldest machine tool. The main function of a lathe is to
remove metal from a piece of work to give it the required shape and size.

Main parts of Lathe machine :

1. Bed

2. Headstock

3. Tailstock

4. Carriage

5. Feed m/s 6. Screw cutting m/s

Specifications of Lathe machine:

Height of centres measured from bed :

Swing dia over bed :

Length between two centres :

Swing dia over carriage :

Max. bar diameter :

Length of bed

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Drilling machine :
It is one of the most important machine tools in a workshop. In this
workshop both radial and piller drilling machines are used.

Main parts of Drilling machine:

1. Base
2. Column
3. Radial arm
4. Drill head
5. Spindle speed and feed m/s

Specifications of Drilling machine:

Max. size of drill possible :

Table diameter :

Max. spindle travel :

No. of spindle speeds :

Feed available :

Power input :

Floor space reqd. :

Net weight of machine :

For specially Radial drilling machine

Dia of column :

Length of arm ;

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Milling machine :
A milling machine is a machine tool used for the complex shaping of metal
and other solid materials. Its basic form is that of a rotating cutter or endmill which
rotates about the spindle axis (similar to a drill), and a movable table to which the
workpiece is affixed. That is to say the cutting tool generally remains stationary
(except for its rotation) while the workpiece moves to accomplish the cutting
action. Milling machines may be operated manually or under computer numerical
control
Milling machines can perform a vast number of complex operations, such as
slot cutting, planing, drilling, rebating, routing, etc.
Cutting fluid is often pumped to the cutting site to cool and lubricate the cut,
and to sluice away the resulting swarf.

Shaping machine :
The shaper is a reciprocating type of machine tool intended
primarily to produce flat surface. These surfaces may be horizontal,
vertical or inclined. In general, the shaper can produce any surface
composed of straight line elements.

Principal parts of shaper:
1. Base
2. Column
3. Crossrail
4. Saddle
5. Table
6. Ram
7. Toolhead

Specifications of shaping machine:

1. Max. length of stroke
2. Type of drive
3. Power input
4. Floor space
5. Weight m/c
6. Cutting to return stroke ratio

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Shaper mechanism :

1. Crank and slotted link m/s
2. Withworth quick returm m/s
3. Hydraulic shaper m/s

Welding machine :
welding is widely used by metalworkers in the fabrication, maintenance, and
repair of parts and structures. While there are many methods for joining metals,
welding is one of the most convenient and rapid methods available. The term
welding refers to the process of joining metals by heating them to their melting
temperature and causing the molten metal to flow together.

Gas welding :
One of the most popular welding methods uses a gas flame as a source of
heat. In the oxyfuel gas welding process, heat is produced by burning a
combustible gas, such as MAPP (methylacetylene-propadiene)
or acetylene, mixed with oxygen. Gas welding is widely used in maintenance and
repair work because of the ease in transporting oxygen and fuel cylinders.

Arc welding :
Arc welding is a process that uses an electric arc to join the metals being
welded. A distinct advantage of arc welding over gas welding is the concentration
of heat. In gas welding the flame spreads over a large area, sometimes causing heat
distortion. The concentration of heat, characteristic of arc welding, is an advantage
because less heat spread reduces buckling and warping. This heat concentration
also increases the depth of penetration and speeds up the welding operation;
therefore, you will find that arc welding is often more practical and economical
than gas welding.

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Hydraulic power press :
The hydraulic press is one of the oldest of the basic machine tools. In its
modern form, is well adapted to presswork ranging from coining jewelry to forging
aircraft parts. Modern hydraulic presses are, in some cases, better suited to
applications where the mechanical press has been traditionally more popular.

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BOILER OR STEAM GENERATORS
Introduction : A boiler may be defined as a closed vessel in which steam is
produced from combustion of fuel.

Areas of application :
 In chemical industries.
 In pharmaceutical industries.
 Textile industries.
 Sugar factory.
 For generating power in steam turbine.

Classification of Boiler :
1) Horizontal , vertical or inlined
2) Fire tube and water tube
3) Externally fired and Externally fired
4) Forced circulation and natural circulation
5) High pressure and low pressure boilers
6) Stationary and portable
7) Single tube and multi-tube boilers

Difference between fire tube and water tube boilers
Sl. Fire tube boiler Water tube boiler
No
1. The hot gases from the furnace The water circulates inside the tubes
pass through the tubes which are which are surrounded by hot gasses
surrounds by water. from the furnace

2. It can generate steam pressure up ……….16.5 bar
to 24.5 bar

3. The rate of generation of steam is ………….450tonnes/hr

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low up to 9tonnes/hr

4. The floor area required is more. …………. less.

5. Overall efficiency is 75% ………… 75%

6. Transportation and erection is …………easy
difficult.

7. It is prepared for fixed loads. …………Fluctuation loads

8. Operating cost is low ……….high

9. Bursting chances are less ……….more

10. Not suitable for large plants Suitable……

BOILER MOUNTINGS AND ACCESSORIES

Boiler mountings : These are the fittings, which are mounted on the boiler
for the satisfactory functioning, efficient working, easy maintenance, and the safety
of the Boiler.

1. Water level indicator : It indicates the water level inside the boiler.
2. Pressure Gauges : Used to measure the pressure of the steam inside the
boiler.
3. Safety Valve : It prevents the boiler from explosions due to excessive
internal pressure of steam.
4. Steam Stop valve : It is used to control the flow of the steam from with in
the boiler and to stop it completely when required.
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5. Blow off Valve or cock : It is use to remove the sediments or mud deposited
at the bottom of the boiler .
6. Feed check Valve : control the flow of water from the feed pump to the
boiler and to prevent the back flow of water from boiler to pump.

Boiler Accessories: The are required to improve the efficiency of steam
power plant and to enable for the proper working of the boiler. These are not
directly mounted on the boiler.

1. Economizer : Maximum amount of heat from the gases should be recovered
before it escapes to the chimney.
2. Air pre-heater : Recovers the heat in the exhaust gases by heating the air
supplied to the furnace of the boiler.
3. Super heater: Increase the temperature of the steam above saturation
temperature.
4. Feed pump : It is used to force the feed water at high pressure into the
boiler.
5. Steam separator : It is used to separate the water particles which decrease
the economy and efficiency of steam turbines.
6. Stem Trap : It is used to drain off the condensed water accumulating in the
steam pipelines.

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THERMAX BOILER
Type of boiler : Fire tube boiler

Capacity : 3 ton

Chimney height : 37 m

Efficiency : high

Working pressure : 10.5kg/cm2

Working temperature : 180 oC

Fuel used : furnace oil , LPG

NESTLER BOILER
Type of boiler : Fire tube boiler

Capacity : 4 ton

Chimney height : 41 m

Efficiency : low


Working temperature : 180 oC


Working temperature : 180 OC

Fuel used : furnace oil , LPG

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BOILER MAINTENANCE
Water level :
 Low water controls are designed and installed to minimize overheating to
boiler parts.
 Low water cut-offs are designed to shutdown the burner equipment in the
event the water level falls below a specific point.
 Periodic draining and testing of the low water cut-off and gage glass will
confirm reliability of these controls. Draining the water chamber of the low
water cut-off removes sludge and sediment as well as simulating a low
water condition to shutdown the burner.

Pressure :

 Steam gages let the operator know what pressure is in the boiler and steam
system. Inaccurate or broken steam gages must be replaced.
 Safety valves are designed to lift in the event the boiler pressure reaches the
safety valve set point.
 Properly set and operating safety valves will prevent a boiler from
exploding due to an overpressure condition.

Make -Up :

 Feed water controls and water treatment programs are essential to boiler
operation.
 The make-up water and condensate return must be treated to remove scale
and sludge producing elements.

Scale :

 Scale deposits adhering to waterside surfaces will insulate boiler steel and
cause overheating.
 Scale deposits will also cause the boiler to operate inefficiently by using
more fuel to produce the steam your process requires, resulting in higher fuel
costs.

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Cost :

 Even if boiler insurance is available, the deductible will still account for
expensive out-of-pocket costs.
 Welded repairs and tube replacement are expensive and will include boiler
and production downtime.
 Having insurance may be of little comfort when your boiler is down and
customers are waiting for service.
 In addition, if you are trying to run a business, your customers or employees
may not be too happy to hear that the system is down from minor
maintenance oversights.

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EFFLUENT TREATMENT PLANT (E.T.P)
Effluent Treatment Plants or ETPs are used by leading companies in the
pharmaceutical and chemical industry to purify water and remove any toxic and
non effluent-treatment-plant toxic materials or chemicals from it. These plants are
used by all companies for environment protection. An etp plant is a plant where the
treatment of industrial effluents and waste waters is done. Effluent treatment is
basically waste treatment.

Importance of ETP Plants :
The treatment of effluents in pharmaceutical industry is essential to prevent
pollution of the receiving water. The effluent water treatment plants are installed to
reduce the possibility of pollution, biodegradable organics If left unsolved, the
levels of contamination in the process of purification could damage bacterial
treatment beds and lead to pollution of controlled waters.

ETP Plants in Pharmaceutical Industry :
The ETP plants are used widely in pharmaceutical industry to remove the
effluents from the bulk drugs. During the manufacturing process of drugs, varied
effluents and contaminants are produced. The effluent treatment plants are used in
the removal of high amount of organics, debris, dirt, grit, pollution, toxic, non toxic
materials, polymers etc. from drugs and other medicated stuff. The ETP plants use
evaporation and drying methods, and other auxiliary techniques such as
centrifuging, filtration, incineration for chemical processing and effluent treatment.

Application of ETP Plants :

 Pharmaceuticals
 Chemicals
 Water waste management systems
 Leather industry and tanneries

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REVERSE OSMOSIS PLANT
Need :

Scarcity of good quality water has increased our dependence on ground water
sources. This brackish or saline water is unfit for drinking or for industrial use
unless properly treated. Reverse osmosis, a membrane desalination process
increasingly used worldwide, purifies brackish water for drinking and industrials
purposes.

Reverse osmosis membrane technology produces water with very low dissolved
solids and which is also free from particulate, colloidal and organics matter

Features :

• Compact unit with robust mild steel powder coated frame .

• Efficiently removes up to 95% of total dissolved solids (TDS) or salinity,
producing water which is clear & pleasant to taste.

• Range of models with capacities from 30 L/h up to 1000 L/h.

• Built in safety features to protect high pressure pump & membranes.

• Capable of handling waters with TDS levels between 1500 to 2500 ppm
depending on the model.

• Fully assembled and tested before dispatch.

• On-line device to monitor treated water quality.

Operation :

The raw water from over head tank is chlorinated for dis-infection and is
passed through a pressure sand filter to remove all suspended and turbid particle
and through an activated carbon filter to remove any colour, sell excess then
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through softening plant for reduction of hardness. This process treated water is
then pumped through the R.O plant and PH is corrected to make potable.

Advantages :

•The most economical &efficient method of dissolved solids removal.

• Easy to startup and uses very little space on solids in feed water.

• Can handle fluctuations of total dissolved solids removal.

• Easy availability of spares and service.

• Short delivery periods.

Applications :

• Hygienic drinking water hotels ,restaurants, hospitals and residences.

• Mineral water plants.

• High purity water for hospital for use in dialysis units.

• As a retrofit to de-mineralization’s plants in industries to reduce regeneration
chemicals.

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AIR COMPRESSORS
An air compressor is a device that converts power (usually from an electric
motor, a diesel engine or a gasoline engine) into kinetic energy by compressing
and pressurizing air.

Types of air compressor:

1. According to the design and principle of operation
1. Reciprocating compressor
2. Rotary screw compressor
2. According to the number of stages
1. Single stage compressor
2. Multi stage compressor
3. According to the pressure limits
1. Low pressure compressors
2. Medium pressure compressors
3. High pressure compressors
4. Super high pressure compressors
4. According to the capacity
1. Low capacity compressors
2. Medium capacity compressors
3. High capacity compressors
5. According to the method of cooling
1. Air cooled compressor
2. Water cooled compressor

Uses of Compressed air :

 Operating tools in factories.
 Operating drills and hammers.
 For tunneling and milling.
 Starting diesel engine.
 Operating brakes on buses, trucks and trains.
 In air conditioning system and ventilation

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 KIRLOSKAR PNEUMATIC CO. LTD, PUNE.

Specifications :

Model : TC200M SL.No : AB0592

Bore : 215.5mm Stroke : 190mm

R.P.M : 525 Pressure : 7kg/cm2

Prime mover : 37kW F.A.D : 5.40 m3/min

Capacity : 200 cfm

 KHOSLA INDAIR LTD.

Specifications :

Type : VYDT Model : 10050

Capacity : 3.58 m3/min RPM : 800

Pressure : 7 kg/cm2

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KHOSLA air compressors model VYDT

The compressor is a vertical, single cylinder , two stage , non lubricated ,
water cooled machine.

The differential type piston is designed such that air is compressed during
both upward and downward stroke. The upper portion of piston dia 250mm acts as
low pressure piston whereas the bottom portion piston dia 210mm acts as high
pressure piston.

The piston is connected to the crankshaft through a piston rod, crosshead and
connecting rod. Air is sucked through suction filter and the suction valves in the
cylinder during upward stroke and delivered through a water cooled intercooler
where is cooled near to ambient temperature. This air is sucked through suction
valves in the bottom side of the cylinder during the upward stroke of the piston.
Air is again compressed during the downward stroke and delivered to receiver tank
through an after cooler

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Constructional Parts :
1. Frame : Made up of cast iron ,for maintaining accurate alignment of
machine.

2. Crankshaft : This runs on white metal bearings and fitted with two
counter weights for balancing all revolving masses.

3. Connecting rod : This connects crankshaft and piston. This helps to
transmit power from crankshaft to piston.

4. Cross head and Cross head guide : For to provide maximum life to the
piston rod and its packing.

5. Cylinder : Made of graded cast iron , is fitted one end with detachable
cylinder head provided water jackets for efficient cooling .

6. Piston : Made of aluminum having low inertia. This is fitted with Teflon
sealing rings and bearing rings.

7. Piston rod and gland packing : Made of forged steel chrome plated are
fitted to have a wear resistance, gland packing are provided to seal the
leakage of compressed air gas.

8. Valves : Alloy steel plate type valves with lift and large flow area are
provided for longer life. Suction valve is sucks the air from atmosphere .
Delivery valve is delivers the compressed air to the receiver.

9. Intercooler : mounted by side of the cylinder flanges and having copper
tubes and water circulated outside the tubes. Thus effectively reduce the
temperature of compressed air.

Lubrication system :
 Main parts are like bearings, big end and small end of connecting rod and
guide are lubricated under by gear

 Piston and cylinder are self lubricated as they are fitted teflon rings

 Pressure should be always 1.5 to 2.0 kg/cm2.
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Recommended grades of Lub.oil

 Servo System 121
 Bharat turgona 30
 Bharat Cabol 41
 Stadela 30
 Caltex algol oil

Water Cooling systems :

There are three arrangements for water cooling system. They are

1. Waste water cooling circuit.

2. Closed circuit with atmosphere cooling tank for discharge water pump to
supply forced feed water

3. Closed circuit cooling system with an over head tank placed at height of
minimum 8m for gravity feed and water pump with a float switch for pump
control. Provision should be made for a tap in all cases for draining the
cylinders where there is a risk of freezing.

Quantity of water required : 30 liters per min

Maintenance
1. Filtered air and good quality of oil should be used.
2. Hot Soap or potassium solution for the air circuit cleaning should be used.
3. Anticorrosive chemical solution should be used for removal scale formation.
4. Maintenance schedule for Khosla Air Compressor

DAILY

1. Check oil level in crankcase and fill if necessary
2. Drain moisture from the air receiver .
3. Drain moisture from the moisture tap.
4. Drain moisture oil from Intercooler ,auxiliary air receiver.
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5. Drain moisture from aftercooler , if provided.
6. Safety valves to be checked by manual operation.
7. Check the lub.oil pressure after starting.
8. Check pressure regulator functioning.

EVERY 250 HOURS

1. Clean air suction filter element with compressed oil.
2. Check the V-belts tensions and adjust.
3. Clean the moisture trap felt element.
4. Check that safety valve blows at correct pressure.
5. Clean the Air filters on piston guide.

EVERY 500 HOURS

1. Clean the suction filter element.
2. Check and clean pressure regulator.
3. Check safety valve setting.
4. Clean the moisture trap felt element.
5. Clean the air filters on piston guide.

EVERY 1000 HOURS

1. Carry out servicing due at 250 and 500hrs
2. Clean the suction and delivery valve. check and replace the worn out parts.
3. Check and decompressor piston.
4. Open the inspection cover of cylinder water jackets and check for sludge and
scale formation and clean if necessary.
5. Clean automatic moisture trap if provided.
6. Replace the filters on the piston guide

For more maintenance procedure refer the user maintenance manual
provided by manufacturer.

36

Compressor Accessories

Non return valves :

1. Stop valve : for unidirectional flow of air this valve is used. It is located
between compressor delivery pipe and inlet pipe of receiver .
Function: It prevents back pressure due to high pressure of air in receiver

2. Safety valve : It is mounted on the receiver which blows off the air when the
pressure exceeds preset value
Function : saves the unit from bursting or damaging.

3. Suction silencer : It is fitted on air intake pipe.
Function: To damp the noise developed due to vibrations in sucked air
4. After cooler : To reduce temperature and contamination of the delivered
air.

5. Moisture separator : To separate the moisture from delivered air. This
device is put next to aftercooler.

6. Receiver : To store the compressed air .

7. Low water pressure safety switch : If the water pressure falls below the
pre-determined , it stops the prime mover. This prevents the overheating. A
alarm also connected electrically to sound as soos as .

8. Low oil pressure safety switch : If the oil pressure falls below the pre
determined ,it stops the prime mover , it stops the prime mover. This
prevents the overheating. A alarm also connected electrically to sound as
soos as .

37

DIESEL GENERATORS
A diesel generator is the combination of a diesel engine with an electrical
generator (often an alternator) to generate electrical energy.
Diesel engine provides the most economical means of generating electricity.
Area of application :
 Used in places without connection to the power grid.
 As emergency power-supply if the grid fails.
 For more complex applications such as peak-lopping.
Generator size:

Generator size are indicated by load carrying capacity as in terms of kW or
kVA. Generator size are vary from 8kW(11kVA) to 2000kW (2500kVA,three
phase)

38

General layout of diesel generator :

General parts of Diesel Engine :

1. Cylinder 2. Cylinder head Piston

3. Piston 4. Piston rings

5. Gudgeon pin 6. Connecting rod

7. Crank 8. Crankshaft

9. Engine bearing 10. Crank case

11. Flywheel 12. Governor

13. Valves and valve operating mechanism

14. Fuel pump 15. Fuel injector

39

Maintenance :
Preventive maintenance :---

Because of the durability of diesel engines, most maintenance is preventive in
nature. Preventive diesel engine maintenance consists of the following operations:

• General inspection
• Lubrication service
• Cooling system service
• Fuel system service
• Servicing and testing starting batteries
• Regular engine exercise

General inspection :
Exhaust system : Inspect the entire exhaust system including the
exhaust manifold, muffler and exhaust pipe. Check
for leaks at all connections, welds, gaskets and
joints, Repair any
leaks immediately.

Fuel system : Inspect the fuel supply lines, return lines, filters and
fittings for cracks or abrasions. Repair any leaks or alter line
routing to eliminate wear immediately.
DC electrical system: Check the terminals on the
starting batteries for clean and tight connections.
Loose or corroded connections create resistance
which can hinder starting.
Engine: Monitor fluid levels, oil pressure and coolant
temperatures frequently. Look and listen for changes in
engine performance, sound, or appearance that will
indicate that service or repair is needed. Be alert for
misfires, vibration, excessive exhaust smoke, loss of
power or increases in oil or fuel consumption.

40

Lubrication service : Check the engine oil level when the engine is shut down.
Keep the oil level as near as possible to the “full” mark
on the dipstick by adding the same quality and brand of oil.

Cooling system service : Check the coolant level during shutdown periods.
Remove the radiator cap after allowing the engine to cool and, if necessary, add
coolant until the level is about 3/4-inch below the radiator cap lower sealing
surface. Use a coolant solution as recommended by the engine manufacturer.

Fuel system service : The charge-air piping and hoses should be inspected daily
for leaks, holes, cracks or loose connections. Tighten the hose clamps as necessary.
Also, inspect the charge-air cooler for dirt and debris that may be blocking the fins.
Check for cracks, holes or other
damage.

Conclusion :
Preventive maintenance for diesel engine generators plays a critical role in
maximizing reliability, minimizing repairs and reducing long term costs.

41

Part – C
(Production Departments)

42

CONDOM PLANT

PRIMARY PRODUCTION DEPARTMENT
In this section the production is based on the Japanese technology with
the technical collaboration of M/s. OKAMOTO RIKEN GOMU CO. LTD.,
Japan for manufacturing. The production/manufacturing involves three process.

 Compounding
 Moulding
 Valcunizing

In the compounding process the chemical dispersion is prepared using ball
mill/attritor mill. After mixing the chemicals will be supplied through supply tank
to the molding section. In molding dipping process is done and after undergoing
several process like folding and washing the product pass on to the vulcanizing
process. After the vulcanizing only we get the final product. All these process are
done through automatic machines.
If automatic machines fails manual vulcanizing process is done. After the
process the product may goes to the half product quality assurance department

Highest production : 0.8462mpcs on 24/11/2011
Lowest inspection rejection : 1.96mpcs on 26/09/2011

43

Products of HLL Lifecare Limited :

Popular brands which are produced by HLL
Nirodh – free supply
Nirodh – New lubricated
Deluxe
Super deluxe
Sawan
Masti
Bliss
Moods
Rakshak
Share
Nymph
Ustad
Sparsh
Pick-me

Company also export condoms to Saudi Arabia, UAE, Kenya, USA,
Mauritius & Oman

44

Introduction to the department :
It is key dept. having compounding moulding and vulcanization as sub
section of dept. Actual production of condoms up to half product stage is
manufactured Controlling officer Asst. G.M (primary) is responsible for all
activities pertaining to the dept.

Strength of section
Junior officers 02
Supervisors 03
Grade IV 17
Grade I/II 06
Grade I.D scale 11

45

Inter-relation with other departments :

Mechanical Engineering dept. -For various maintenance of machine
pertaining to mechanical section.
Electrical Engineering dept. - For various maintenance of machine
pertaining to electrical section.
Quality Control Lab dept -For getting feed back quality of
product.
Human Recourse dept. -For imparting training to employees
in respect of SHEMS and QMS.
Stores dept. -To know the latest position of
Chemical.
Purchase dept. -To know the emergency materials.
Accounts dept. -For getting budget approval and
Writing off materials.
P.P.C dept. -For production planning.
Safety dept. -For monitoring work environment and
Employees safety.
Quality Assurance dept. -For implementing and verifying the
Predefined standards.
First Aid -For getting first aid for injured
employee at primary dept.

46

Flow chart of primary department :

Compounding & mixing tank

↓
Supply tank

↓
Dipping tank

↓
Drying & Pre-vulcanization

↓
Beading Edge Rolling Unit

↓
Pre-vulcanization Drying Unit

↓
Swelling Bath

↓
Anti-Sticking Bath Unit

↓
Stripping of dried condoms

↓ (Empty mould washing unit &re-circulation for dipping of empty moulds)
Automatic vulcanizing of condoms

47

Transfer of Raw latex & compounding , moulding & vulcanizing
chemicals from stores :

e
Through IMIS material are obtained. Drum Trolley, Platform trolley
equipments are used for transportation of material from stores.

Preparation of Dispersion solution :

Purpose : To supply dispersion solution for compounding
Procedure :1. Check the ball weights periodically it should be 120kg ±5
for Porcelain balls & 200kg ±5 for Zirconium balls.
2. Add 25±1 liters of 1% ammonia in Attritor mill & then
switched on the Attritor mill & kept run for 8hr.
3. After completion of milling time it should be stopped.
4. Check the settling time of dispersion.
5. If settling time is less than 190sec, then Attritor mill can be
operated another half an hour.
6. Repeat this until settling time reaches above 190sec.
7. Then unload the Dispersion from Attritor mill.
8. Weights of balls should be checked once in two months.

Preparation of 3% to 5% Liquid Ammonia :

Purpose : To supply 3 to 5% ammonia solution for compounding,
moulding & vulcanizing.
Material and Equipment required : Ammonia absorption unit
Procedure : connect ammonia cylinder to the absorption unit & adjust
the flow rate of gas & water for getting required output.

Preparation of 1% to 2% Liquid Ammonia :

Purpose : To supply for compounding section
Material and Equipment required : Preparation tank
Procedure : 1. Cleaning tanks
2. Pumping 6 barrels of raw latex having 194 ±2kg of each.
3. Adjust required rpm 25±5 & switch on agitator in mixing
tank.
4. Add 10% Casein to mixing tank as per PHR & 10±0.5
liters.
48

5. Wait for 10 minutes.
6. add set sit/ pilcure solution as per PHR diluted with 1%
ammonia 10±0.5 liters 1% ammonia.
8. Add Nocceler TP/Robac SDBC as per PHR 1.4±0.11kg
diluted to liters of 1% ammonia.
10. Pumping mixed dispersion dilution with 1% ammonia
solution 45±0.5 liters.
11. Add 1% ammonia solution 28±0.5liters.
12. Stop agitator & adjust agitator speed for 15±5 rpm then
start agitator for 2hr.
13. Set temperature 56±2oC & start the heat for required
duration by opening steam valve.
14. After required duration heating stop the steam valve
& open the process cool this mixture to room
temperature.
15. Sending of sample to lab for skin material test.
16. Compounding latex which is being as per specification to
be transferred to the supply tank for maturation. After
maturation this will be required to supply to dipping tank
for moulding purpose.
17. checking of cure of supply tanks before supply to dipping
tanks.
18. supply of compounded latex to moulding section for
dipping .

Preparation of Casein solution :

Purpose : To supply 10% Casein solution for compounding process.
Material and equipment : Steel bucket, weighing balance
Procedure : 1. Weight 10% of required quantity of Casein powder in a
container & mix with 80% of required quantity of
lukewarm soft water.
2. Add 10% of required quantity of 3 to 5% NH4 solution
& stir well

49

Procedure to adjust TS & Viscosity of Compound latex :

Purpose : To adjust parameter of compounded latex within range.
Procedure : 1. If viscosity & TS of compounded latex found to be more
than limit , it has to be adjusted by adding 1% to 2% NH4
2. If viscosity & TS of compounded latex found to be less
the limit, then it has to be adjusted by adding compounded
+
latex of TS 55 /-2%.

Pink pigment preparation for moulding pink condoms :

Purpose : To adjust colour of latex to pink for the moulding of pink
Condoms
Material & equipment required : weighing balance
Procedure : 1. Pink is arrived by adding red & violet paste.
2. For 100kgs DRC compounded latex Red-FP 551-50 gms
& mixed with violet FP 591-14 gms.

Moulding and vulcanizing condoms :

Purpose : To manufacture of latex condoms.
Material and equipment : Moulding machine , vulcanizing machine,
chemical dozing pump, weighing balance,
image printer
procedure : 1. Before starting of machine check the required parameter.
a) dipping temperature
b) level of latex in the range of 160 to 165 mm before dipping.
c) drying temperature
d) Beading unit
e) Swelling tank
f) Antisticking bath
2. Test the cure of concerned supply tank. If cure is not ok adjust
the cure or over cure latex to required cure.
3. Check the dipping tank latex cure chloroform test & adjust the
cure if required.
4. Dip the moulds in dipping tank as per the validated chain speed

50

& depending upon the drying conditions and output required.
5. Ensure the identification mark on the condoms after first dip, the
identification mark first digit indicates name of manufacturer, second
digit indicates year of manufacture, third digit indicates scheme of
product.
6. Check the drying of condoms in drying chamber & condoms
before entering for second dipping & adjust the conditions as per
required drying & specification.
7. Adjust edge roll formation on the glass mould to required
specification after getting feed back from QC dept.
8. Check the pre-vulcanization temperature as per specification.
9. Check the proper swelling of condoms in stripping area.
10. Check the % of NH4 in swelling tank.
11. Check the condition of anti-sticking bath.
12. & replenish the tank with the anti-sticker as per norms.
13. Stripping of swelled condoms with the help of silica slurry
pump in stripping unit.
14. Check the water rinsing of stripped moulds.
15. Washing of stripped glass tank with soap solution &
replenishing the washing tank with soap solution as per norms.
16. Check the proper functioning of washing brushes .
17. Dipping of fresh moulds after cooling.
18. Adjust the steam soaking inside the dipping room in range of
0.2 to 2.00 kg/cm2

51

Stopping procedure of moulding machine at the time scheduled
clarification, annual maintenance, process problems, mechanical
/electrical breakdown & holiday :

1. Switch of all drying & vulcanizing heaters & blowers.
2. After 10 min close the valve of latex supply to dipping tank.
3. Close the steam –soaking valve.
4. Take dipping tank down.
5. Cover the dipping tank with PVC plastic cover if latex withdrawal is late.
6. Strip single dip condom by water at waste strip unit.
7. Switch off the beading unit.
8. Stop the slurry pump.
9. Drain anti=sticking bath
10.Take the swelling tank down & drain the NH3
11.Switch off the air cleaning unit.
12.Close the particular steam valve at steam header.
13.Take over the latex from dipping tank for filtering / centrifuging.
14.After withdrawal of compounded latex clean the dipping tank thoroughly
with water, sponge /cloth.
15.Clean the inside channel of dipping tank with the help of rope & plug.
16.Incase of delay in the withdrawal of compounded latex / to start process the
dipping temperature should be maintained less than 20oC.
17.Switch off the chain conveyor movement after stripping all single dipped
condoms.
18.Switch off the washing unit.
19.Switch off the hot water pump.
20.Switch off the recycle water pump.

52

Procedure for scheduled clarification :

Purpose : To keep machine performance good.
Procedure : 1. Clarification shall be taken twice in month for individual
machine.
2. Stopping the machine as per schedule & allotting the
required works to the concerned workmen.
3. Chalking work list & communicating with engineering
dept.
4. Monitoring & completion of work & giving clean chit to
engineering dept.

Procedure for Annual Clarification :

Purpose : To keep the machine in good condition.
Procedure : 1. Annual clarification or preventive maintenance is to be
taken once in two years for individual machine.
2. Chalking of work list & communicating to engineering
dept.
3. Monitoring the work & completion of work as per
schedule.

Corrective action for defects :

Purpose : To check the HP rejection.

Nature of defects.
1. Inside sticking
2. Twisted edge roll & bad edge roll
3. Lip cut
4. High JIS rate (Japanese Industries Standard)
5. Weak spot
6. Wrinkle
7. High body thickness
8. Low length
9. Bump

53

Procedure : 1. For inside sticking check the concentrated of slurry &
maintain it as per working parameter. Check the cure of
dipping latex. check the dozing of NH3 in swelling tank.
Check the foam formation in slurry pit.
2. For twisted edge roll & bad edge roll. Check the cure of
dipping latex & adjust to slight under to correct cure if
required. Check the drying condition & keep required
temperature. Check the level of dipping & adjust if
required.
3. For lip cut defects ,check the drying condition and
maintain temperature. Check the cure of dipping latex and
adjust to correct cure or slight under cure ,check the
thickness of edge roll & adjust as required. Reduce the
chain speed looking at drying condition.
4. For high JIS rate (water leakage) or low resistance, check
the contamination of dipping latex due to silica falling on it
from chain. Check proper drying of dipping moulds. Check
the proper alignment of slurry jet. Check the proper mould
washing. Check foreign particles in dipping & swelling
tank. Check mould collision due to improper tension of
chain.
5. For defects like wrinkle ,check the conc. Of swelling bath
& add 3 to 5% NH3 if required. Check slurry conc. Shall
be 2.5 % to 7%.
6. For high body thickness ,add required quantity of 1% or
2% ammonia in dipping tank latex. Adjust the chain speed
& soaking to be maintained.
7. For Bump defects, check the looseness of chain, adjust the
position of sprocket, check the correct mounting of moulds
-retighten the moulds, check latex coagulation touching the
moulds, clean the dipping tank wall & remove coagulum.

54

Vulcanization process :

The reaction between rubber and sulphur is known as vulcanization.
Matt & equipment required : vulcanizing machine, dust collector, slurry
pump, moisture balance.
Procedure : 1. Prepare the slurry and maintain slurry total solid as per
validated parameter in slurry pit, check the slurry total
solid twice in a shift.

2. Collection of condoms for vulcanization to mesh barrel
with the help of pneumatic pipeline.
3. Setting of vulcanization temperature as per norms.
4. collect the dust from dust collector min twice in week &
Dumped to waste silica sludge pit.

Manual vulcanization process :

Procedure. 1. This activity is to be done when automatic vulcanization
machine is under breakdown or under observation.
2. Set the vulcanization temperature as per norms & transfer
the condoms to vulcanization chamber.
3. Vulcanize the condoms for 30 to 45 minutes.
4. Transfer the vulcanized lots to quenching barrel for
quenching the product.
5. Transfer the quenched condoms to HP section for quality
check. Operators has ensure the gloves & mask during
handling.

55

Working standard parameters & standard norms of consuming
chemicals :

Working parameters
Compounding section :
Pre-vulcanization time : 10 to 18 hrs
Pre-vulcanization temp : 50 to 58oC
Attritor mill time : 6 to 10 hrs
Size of porcelain/zirconium balls in attritor mill : 4mm to 8mm
Ammonia conc.for praperation : 3 to 5 %
Maturation of compounded latex : 50 to 120 hrs
Dispersion solution setting time : above 190 sec

Moulding section :
Chain speed : 7.5 to 11.50 m/min
Dipping tank latex temp. : 27 to 31oC
Hot air fan temp : 130 to 152 oC
Hot air blower speed : 800 to 1300 rpm
Temp first drying booth : 65 to 120 oC
Temp after in edge roll : 65 to 110 oC
Conc. Of ammonia in swelling bath : 1 to 5 %
Temp of swelling bath : 25 to 50 oC
Temp of washing bath : 30 to 50 oC
Temp of hot water : 70 to 90 oC
HCL for mould cleaning : 20±5 liters
Hydro fluoride : 20±5 liters

Vulcanization section :
temp of hot air supply :
units to dehydrator : 90 to 150 oC
vulcanization temp : 75 to 100 oC
manual vulcanization : 75 to 100 oC
conc. of slurry : 3 to 7 %

56

Working norms for the consumption of chemicals :
Items norms kgs/mpcs
Raw latex 2184
Ammonia 150
Sulphur 20
Zinc oxide 13
Nocceler TP/SDBC 2.89
Anti-oxidant 0.7
Darvan-I 0.67
Darvan-II 0.67
Tamol 0.2
Casein 1.60
Pigment paste red 1.00 for pink condoms
Pigment paste violet 0.3 ---------------------
Pigment paste 1.5 for violet condoms
Pigment paste blue 1.5 for violet condoms
Pigment paste green 2.5 for violet condoms
Pigment paste orange 2.00 for violet condoms

Moulding & vulcanization :
Items norms kgs/mpcs
Anti-sticking agent 35
Silica 175
De-foaming agents 22
Washing agents 03

Latex skin controlled parameters :

For mixing tank latex :
Viscosity :24 to 40 centipoise
TS :53 to 57%
MST :190 to 1500 sec
HST :635 to 900 sec

For supply tank :
Viscosity :17 to 24 centipoise
TS :49 to 53%
HST :635 to 900 sec
Compounding ratio : parts per hundred ratio
57

For preparation of dispersion :
Sulphur : 1.50
Zinc oxide : 0.90
Anti-oxidant : 0.50
Darvan-I : 0.045
Darvan–II : 0.045
Tamol : 0.014
10% casein soln : 0.128

For compounding raw latex :
Raw latex : 100
1 to 2 % ammonia solution : 0.147
10% casein solution : 0.02 to 0.1
Set sit / pilcure : 0.50
Nocculer TP/SDBC : 0.20
Dispersion : as above

Ratio of colour pigment :
Green : 160gm/100 rubber
Orange : 125gm/100 rubber
Violet : 100gm/100 rubber
Blue : 100gm/100 rubber
Pink : 64gm/100 rubber

Salvaging process :

Procedure : 1. Allotment of lot to be salvaged to the employee who is going to
salvage.
2. Salvaging of condoms by given employee as per training given to him.
3. Entering data of salvaged condoms of good and bad in the format provided &
giving lot for QC to check as per standards.
4. If lot is rejected there by after salvaging by QC, the lot is re-salvaged & given to
QC unit until it is passed in all defects.
5. If lot is rejected due to ERM specification separate identify shall be maintain for
inspection of lot with high voltage. Red colour bags shall be used instead of black
bag for continual improveness.

58

Standard operating procedure for ink jet printers :

Purpose : To operate printer in systematic way.
Procedure :1. Switch on power supply to printer.
2. Switch on printer.
3. Create & select message to be printed on the condoms.
4. Start printing on the single dipped condoms.
5. Stop the printing when there is no condom on moulds.

59

OCP PLANT
The manufacturing process for to make tablets.

Granulation : A granulation is the formation of small agglomerates called
“granules”. Each granule will contain a proper mix of the ingredients of the
formula. Density of the granules can be control by the amount of liquid binding
solution and the mechanical energy created by the type of machine used. The
machines used to blend powders and add liquid are called “granulators”. Some
granulators have the ability to dry the excess moisture.

Many granulators do not have the ability to dry the wet massed granulation;
therefore the wet granulation must be moved to the next unit operation which is
called Drying. The Dry Granulation method uses mechanical force to densify and
compact powders together which forms dry granules .

The final goal is to make a quality tablet with the following attributes:

▪ Good Weight Control
▪ Good Thickness Control
▪ Good Hardness Control
▪ Good Ejection
▪ No Capping
▪ No Lamination
▪ No Sticking
▪ Good Friability
▪ Good Disintegration
▪ Good Dissolution

Why Granulation ?

 To improve powder flow.
 To improve compressibility.
 To reduce fines.
 To control the tendency of powders to segregate.
 To control density.

60

Milling :

Milling equipment is used to Improve flow, reduce segregation,
enhance drying, and limit wide particle size distribution.
Milling machinery used in the preparation of tablet & capsule formulations
can be categorized as to their mechanical energy; Low, Medium or High energy
mills will impart a force on the powders called shear force. Therefore, milling
machinery is defined by Low, Medium and High shear applications.

Tablet Compression :

While an experienced operator can take a marginal granulation
and make a good quality tablet, an inexperienced operator will be unable to
produce a quality tablet. The final granulation to be compressed must have three
basic characteristics, all of which are critical: Flow, Compress and Eject .A tablet
press can be fully automated to the point that it can be operated in a lights out
operation.

Tablet weight control :
Having consistent flow of a granulation provides the needed avenues to
control tablet weights. Consistent tablet weight will result in
repeatable tablet hardness. Tablet hardness is a function of tablet thickness and
tablet weight.

Tablet Coating :
Once a good tablet is made, we often need to add a coating.
The coating can serve many purposes; it makes the tablet stronger and tougher, improves taste,
adds color, and makes the tablet easy to
handle and package. The coating can be a thick sugar based coating or a very thin film. Most
pharmaceutical tablets are coated with a thin film coating. This coating is sprayed as a solution (a
mixture of solids in a liquid). Tablets must be tough enough to tumble while the solution is
added. The solution is distributed from tablet to tablet during the tumbling and drying process.
The spraying, distribution and
drying all takes place at the same time.

Coating Equipment :
Tablet coating equipment combines several technologies and is commonly
referred to as a coating system. This system consists of the coating pan, spraying

61

system, air handling unit, dust collector and controls. The coating pan is really a
drum within a cabinet, allowing
for control of air flow, air temperature and controlled solution application. The
spraying system consists of spraying guns, a solution
pump, tank & mixer and air lines. The solution is pumped into the guns and the air
combines with the solution for atomization into a very fine
mist. The air handling unit (AHU) is basically a way of heating and filtering the
air. Dehumidification and/or humidification maybe be needed depending on your
location and application requirements. The Dust Collector collects the dust during
the preheat and tumbling cycles and the Controls connect all of the components
creating a complete coating system.

Coating process :
Tablets are loaded into the coating pan, creating a bed of tablets. There must be
enough tablets to attain good mixing, but not too many or the tablets will spill
when the door is opened. Consistent batch sizes are important to attain consistent
results. The tablet bed is tumbled slowly, as the warm air is introduced; the dust
collector pulls the dust off the tablets and into a collection bin. When the tablet bed
temperature reaches the proper temperature the spraying can begin. Once tablets
have an initial base coating the spray rate can be increased. The controls are
monitored by the operator or computer, recording data frequently. Tablet
defects can occur if the temperature, spray rate and air volume are allowed to
fluctuate.

Common tablet defects :
 Weight variation
 Friability variation
 Picking & Sticking
 Capping
 Laminating
 Chipping
 Mottled
 Double pressing

Packaging Training : Commonly for packing Blister packing machines are
used. Blister packing machine was formulated a few years later. The most
important reason for introducing blister packaging technology was to offer patients

62

a clearly marked individual dose, enabling them to check whether they had taken
the prescribed drugs on a given day Moreover, the drugs that were not taken
remained in the original package and were fully protected against adverse external
conditions. The patient could handle the blister package more easily and could
store it more conveniently than conventional packages. It is easier
to prove misuse with blister packaging than with conventional packaging. Thus,
blister packages effectively meet the demand for tamper-evident packaging.

Blister packaging components :
The four basic components of pharmaceutical blister packages are the forming
film, the lidding material, the heat-seal coating, and the printing ink.
The forming film is the packaging component that receives the product in
deepdrawn pockets. Plastic forming films such as PVC, polypropylene (PP), and
polyester (PET) can be thermoformed,
but support materials containing aluminum are cold-formed.
The lidding material provides the base or main structural component upon
which the final blister package is built. The surface
of the lidding material must be compatible with the heat-seal coating process.
Heat-seal coatings provide a bond between the plastic blister and the printed
lidding material.
Printing inks provide graphics and aesthetic appeal. They can be applied to
the lidding material by letterpress, gravure, offset,
flexographic, or silk-screen printing
processes.

Blister packaging machinery :
The sequence involves heating the plastic, thermoforming it into
blister cavities, loading the blister with the product, placing lidding material over
the blister, and heat-sealing the package. This can be partially or fully automated.

Capacity of machine : At 60 r.p.m , the cutting stroke blister packing machine is
4strips per second.
one operating person

63

BULK DRUG UNIT (B.D.U)
This unit consists of reactors for stirring different acids or chemicals with steam
for obtaining chemical substance for various tablet production in steroidal or non
steroidal plant

Product Name : Centchroman HCL

Generic name : Ormanloxifen HCL

Manufacturing process stages

Stage 1 : Substitution reaction

Stage 2 : Freidel crafts & condensation reaction

Stage 3 : Demethylisation Reaction

Stage 4 : condensation reaction

Stage 5 : Grindnard reaction

Stage 6 : Hydrogen reaction

Stage 7 : Condensation & Isomerisation reaction

Stage 8 : Finished product acidification

Stage 9 : centchroman HCL

 Production of Centchroman Bulk Durg, which has annual
production capacity of 1,000 kilograms.

There are three main type of reactors :
64

1. Poly-propene (PP reactor) : To stir the acid with steams
2. Glassline reactor (GL reactor) : For final acidification process
3. Stainless steel (SS reactor.

Each having a capacity of 2000liters and working pressure ranges between
1 to 1.8 kg/cm2

Mechanical Utilities :
Chiller unit : It supplies chilled water for reactors for various reactions.

Raw water line : It supplies water to reactors if needed.

Hot water line : It supplies hot water to reactors

De mineralized water line : It supplies purified water if needed.

Steam line : It supplies steam from boiler house to reactors

Compressed air : For various purposes

Air Blowers : To suck the fumes and neutralize it.

Vacuum pump : To suck the chemicals and then passed the reactors

where it needed for process.

Scrubber : To suck the chemicals and then passed the reactors

Pulverizer : For milling powder lumps.

Centrifuge : To separate solid from liquids.

Tray drier : For drying wet granules of powder.

Hydrogen Tank : It stores the hydrogen having capacity of 1200 liters.

65

SANITARY NAPKIN PLANT (S.N.P)
Scope of Plant :
To address the menstrual hygiene needs of the adolescent girls of the country, the
Ministry of Health & Family Welfare, Govt. of India, New Delhi, has launched a
programme to supply Sanitary Napkins in the brand name of Freedays at
Subsidized rates.

Plant Profile :
The new plant was inaugurated on 23 April 2012 by Shri. M. Ayyappan, C&MD,
HLL Lifecare Limited. The production starts from 1 May 2012 and the plant has
yearly 180 M.pcs of napkins production capacity. Daily approximately 4.5 lacks of
napkins are going to produced in this plant. Till today 37 batches are produced. In
one batch there is 1.5 M.pcs napkins are produced.

Products of Plant : Free days –for govt. of India
Puthuyugam –for Tamilnadu govt.

Raw material required :
 Glue polytransparent release paper
 Glue polytransparent construction
 Roll fluff pulp
 release paper width 50mm
 Tissue paper width 155mm
 Non-wooden sheath width 110mm
 Pouches four colour print
 master carton to pack 160 sanitary napkins
 LDPE back sheath width 110mm

66

Quality Control Procedure : during inprocess & finished products.
 Core length : 204mm (210±10mm)
 Core width : 69mm (60-75mm)
 Thickness : 8.5mm(7-10)
 Weight by weighing balance (7.5 to 10gm)
 PH value by PH meter (6 to 8.5)
 Absorbency not less than 20ml

Machine description :

Machine manufacturer Name : Fujian Peixin machine manufacturer industry co
ltd. Chaina.

The machine following main units. They are as follows
1. Pulveriser
2. Web wheel
3. Tissue paper splicing unit
4. Core cutting unit
5. Glue spraying unit (non –wooven)
6. Round sealing unit
7. Release paper cutting & positioning unit
8. Round cutting unit
9. Wing release paper cutting positioning
10. Belt conveyor

The machine fully automatic with servo control. It has capacity of 400-450 napkin
producing capacity in one minute. It has 130 kw power consumption capacity.

Packing department : This is done manually. It includes printed
pouches, napkins, cartons. In one pouch there are 6 napkins are packed.
160 pouches are packed in one master carton box

67

HLL Kanagala Plant History

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