Transcript
Sections of EHS Safety Guideline for Corporate, divisional
and internal audits are divided into six sections:
1. EHS Organization and Management2. Occupational Health and Hygiene3. Electrical, Mechanical, Buildings, Housekeeping
and safe work practices4. Fire Protection and Life Safety5. Environment6. Accident Reporting, investigation and ControlAll the safety systems and rules are covered in
detail in these sections with clear guideline.
Accidents Reporting Lost Time Accident: If a person does not return to work
immediately. Report is sent to Corporate EHS. Reportable Accident:If a person does not return to work within
48 hr. Report is sent to Factory Inspector Serious Accident: Accident which causes death or serious injury.
Report is to be sent to Factory Inspector, DM, Commissioner for workmen compensation
Property damage: Dangerous Occurrence: Incident Reporting: Incident is an accident resulting neither in
injury or property loss. These are also important for reporting and analysis
Work Permit System Work Permits are required before
starting the work. Different Kind of work permits are:
• Height Work Permit• Electrical Work Permit• Confined work Permit• Excavation work permit• Hot Work Permit• Fragile floor work permit etc.
Imp. Safety systems Fencing and guarding of dangerous
machineries and parts Regular testing of Pressure vessels,
Compressed gas cylinder, Safety relief valves etc.
Make, hand signals and testing of lifting gear tools and tackels.
Certificate of registration and testing of boilers.
LEAF GODOWN
Tobacco Plant-Farmers
PurchasesBy ILTD
Storage
Threshing
Inspection
Transport toITD Factory
Receipt atLeaf Godown
Issues to PMD
InfestationControl
Leaf Godown Flow Line
Air Cured and Flue cured tobacco
GLOBAL GRADING SYSTEM – Lamina
Source Plant Position Quality (Color,Ripeness,) Breath Suffix Form Suffix (Threshing) Crop Year
P O X W / T /04
1 2 3 4 5 6
A stands for Flue cured Only A stands for NLS grade (Northern light soil) A1 stands for high sugar flue cured A2 Stands for low sugar Flue Cured
AY stands for KLS (Karnataka Light soil) i.e from Mysore. B denotes the Stem that is air cured.
GLOBAL GRADING SYSTEM – Stem
Random Check of 10%
10% of CFCs checked at random• Infestation, mould, wet mark, oil mark, physical
damage to the packs, bulge CFCs • Weight• Findings noted down in a register
In case of rain damage, oil marks or other damage in transit, ILTD and Leaf HO are informed and the CFCs are sent to the part pallet zone for priority issue
In case of water marks 100% pack deshelled & checked
Stacking Procedure
Stacking – As per put-away list CFCs are stacked in the respective cells.
Example :-
Q / 28 / 2
Row Position Stack
Unloading Infestation Checking
Infestation monitoring by workman Serrico trap monitored for minimum 2 hrs Count = 0 : Stk will be received at rack go-down Count > 1: Stk will be sent to go-down no 14 for
fumigation
Leaf godown capacity
No. of Cells = 3304 (Considering 4 high only) No. of cells reserved for Part Pallet Zone = 124 Cells reserved to first to move CFC’s = 80 Therefore, Total effective bin = (3304-124-80 = 3100* Max Capacity of each cell = 4 CFC’s @ 200 Kg each = 800 Kg
Capacity = 3100 (0.25x720 + 0.75x800)** = 2.4 Mln Kg Assuming 80% efficiency = 2.4 x 0.8 = 1.98 Mln Kg.** Assuming 25% CFC’s of 180 Kg (as 20% is of stem and 5% are some
special kind of lamina which comes in 180 Kg pack
Infestation
Infestation is one major area of concern in tobacco industry.
Infestation control – As tobacco dust in humid atmosphere is ideal for beetle breeding, housekeeping must be in center of the focus.
Type of Infestation control Preventive Curative
Infestation Control
Monitoring Serrico Trap sticker - Serrico trap is located at various
locations to monitor beetle count in that area.
Preventive Treatment Misting - By natural Pyrethrum mixed with water. Fogging - By natural Pyrethrum mixed with fogging oil.
Curative Treatment Fumigation : Fumigation is done by using Phosphin
(aluminum phosphate) for infested tobacco.One tablet/mtr3 in a leak proof chamber for 10 – 12 days is kept.Then it is kept for normalization in open air. This is done in Godown No:14
Introduction
Purpose of PMD?To Convert leaf tobacco of various grades into
Blended Cut Tobacco,Ready to produce cigarettes consistently to give consistency in smoking.
Two Process Line A Tobacco leaf contains Fleshy & Midribs
• Lamina – Fleshy portion of leaf
• Stem – Midribs of the leaf
Two measure differences between Stem and Lamina are:
• 22% m.c. is required in Lamina for making it soft and pliable for cutting while for stem 40% moisture is req.
• 30 CPI is required for lamina cutting while for stem 140 CPI is required.
Because of the above differences, there are separate Processing lines for both
Lamina LineThere are two major steps in Lamina lineLamina Conditioning Lamina cutting and dryingAfter drying Lamina is mixed with the CRS stored in addback bins for final CT which is again processed through cooler.
LAMINA CONDITIONING
Feeding De-shelling
B.T. DeviceInspectionSlicer
DCC & C Blending Bins
Inspection
LAMINA CUTTING AND DRYING
Discharge from Bins Air Lift Sieve
Complex
CuttersSearch & Fill
GFP Weycon
KLD Dryer Cooling and flavoring
Cut Tobacco Bins
Skip Filling and weighment
CTS
By Pass CuttersCRS from Bins
Equipments in Lamina line : ‘U’ Conveyor Bale tilting devices Slicer DCC&C Lamina bins Shieving complex Metal detector assembly Lamina cutter (KTC) Search & fill Weighing con HT (Lamina expansion sys.) KLD
Lamina FeedingFollowing steps are followed: Issue of leaf as per Pick list Lay down in feeding sequence (U-
conveyor is used) De-shelling the lamina cake using
grab hoist and Bale turner Inspection of leaf Cutting in 3 cuts (4 pieces) in slicer Feeding cut leaf to DCCC
Lamina Feeding… U-Conveyor: CFC, after laying down in
sequence, gets auto feed.
De-shelling:Scissors type grab in combination with hoist with 1 Ton capacity is used. Lifting Drive is 1.5 HP and Traverse drive is 0.25 HP
Bale Turner: BTD has a bands within it to receive the bale and discharge it after turning. it helps to expose all the sides of the bale and thus helping to check all the sides for infestation and for mouldy and musty Tobacco.
Slicer: It cuts the bale into 3 cuts (4 pieces). The total cycle time is between 120 and 138
seconds (presently 127 seconds). It consists of Pusher (moves forward/reverse), Knife (moves up/Down) and discharge bend.
Feed of DCC&C is controlled here. This ensures uniform feed to DCC&C Ensures proper conditioning by reducing the feed
size to DCC&C from single bale to 4 pieces.
Lamina Feeding…
Lamina Conditioning Dickinson Direct Conditioning & Casing Cylinder
is used for conditioning of Lamina, It is used for:• De-lamination of leafs• Increasing moisture from 11% to 22% (For preventing
dust formation and degrading at cutter)• Applying suitable casing
DCC&C is a re-circulating rotary conditioning cylinder fitted with pins along the inside to tumble the leaves to allow even conditioning. The moisture of Lamina is increased by a combination of water sprays and steam. DCC&C has casing application arrangement added.
PrincipleThe addition of moisture in DCC&C happens due toCondensation Cold Tobacco comes in contact with hot humid air Condensation of water takes place on the tobacco This is absorbed by the surface of tobacco Approx. 4 to 5% moisture increases by condensation (@ 1%
m.c. increase on every 10 0C rise in temp of lamina)
Direct Absorption of Water The cells of the lamina open up due to heat Water particles penetrate these opened up cells
DCCC.. Cylinder is made from SS sheet 3 mm thk. SS spikes are fitted internally (additional pins at the
feed end) Exterior is insulated with rock wool mineral fiber and
clad in plastic coated mild steel sheet Cylinder Dia:2.1 Mtr, Length:7.2 Mtr Cylinder RPM 8.5 variable mechanically from 4 to 17 Designed flow rate 7000 Kg at 9% m.c. (Inlet) and
8167 Kg at 22% m.c. (Outlet) Product Temperature 15 0C in, 75 0C out Drive: 11 Kw 1400 RPM PA fan Drive: 11 Kw 100 RPM PA fan capacity : 5000 cfm max.
DCCC… Preheat Mode: Preheat of cylinder is done to
prevent excessive heating. In preheat mode, dry heat is only is applied to the cylinder by re-circulating PA through a steam treated heat exchanger mounted inside feed hood.
Run Mode:Steam spray and atomized water spray starts. Heat exchanger is bypassed and heating of PA is done by direct spray of steam.
Change in mode: When product has not been fed for a time in excess of 2 min., the cylinder control switches to preheat mode automatically
CasingCasing is applied to the conditioned lamina
from the discharge end of DCC&C. The suitable casing is used :
• To increase the sugar levels in the tobacco with low natural sugars (For Air cured tobacco).
• To enhance moisture retention of the lamina.• To reduce harshness and bitterness of the smoke.
Lamina BinsPurpose of Lamina Bins: Bulking of processed Lamina Homogenizing of the moisture, temperature and other various
properties of different grades of leaves Proper mixing of the leaves by bulking it in horizontal layers
and discharging in vertical layers at the time of discharge with the help of doffers.
Working Principle: The conditioned tobacco is fed to the master trolley. This master trolley feeds the lamina bin Half by the forward motion Another half by the reverse motion Minimum bulking time required is 2 hrs.
Air-liftbypass
To cutter
Sand
1” gap rollers
¼” sieve
Sieve Complex
Mixed >1” ¼”-1”
¼”- <1/18” >1/4”
1/18”
¼”
Sieve Complex
Sieve complexClassification sizes –1/4”, 1/18” Objectives
Separating thru-quarters ( ¼”)
The thru-quarters by-pass the cutter and are air-lifted to post-cutter line before Search & Fill
Sand is obtained as underflow of 1/18” sieve
Lamina Cutter(s)
Objective: Cut the lamina to required and uniform size, for
filling into cigarettes
Model: KTC and KTC80E
Make is Hauni
Cuts to 30 cpi (0.84mm) normally
40 cpi (0.63mm) for bingo blends
Lamina is fed through a GFP SRB receives the lamina and it ensures even feed to the
cutter using two sensors – stroke length must be optimal for proper compacting of tobacco
Transport chain conveys compacted lamina in cake form to mouthpiece
As tobacco leaves m/piece it is cut by knifes on rotating cutter drum
Grinder constantly sharpens the knife and oscillates along an axis parallel to the drum
Diamond is continuously truing the grinding wheel
Lamina Cutters…
Search & Fill & Weigh Con
Operating principles : It ensure continuous feed to weigh con even incase of any stoppages in up stream. Thus acts as a buffer for 15 minutes.
Weigh ConOperating principles : It weighs & measures the
moisture contents of in coming tobacco & feeds the data to PLC for downstream operations.
Search & Fill
Hauni Tunnel
Operating Principles : Increases the fill value of lamina by charging free
steam through No. of holes across the VOV. The amount of increase in moisture content here is around 2 to 4 % the temperature of cut lamina increases from ambient to 90 0C.
KLD Dryer Dryer is required to reduce the moisture
of the lamina (which is about 24% at the outlet of the HT). The moisture is required upto 14 %.
Dries up the excess moisture from cut lamina keeping the fill value gained.
K L D - DryerMajor components : Cylinder (D-1.9 mtr, L- 10 m, Inclination
50) Paddles(12 nos). Process air and admixed air flow system. Cylinder drive. Water nozzle at exit.
K L D
Process parameters : Inlet mass flow- 6815 kg/ hr. Outlet mass flow- 5825 kg/ hr. Inlet temperature- 85oc. Outlet temperature- 60 to 65oc. Avg. inlet moisture content- 26%. Avg. outlet moisture content- 15%. Operating steam pressure- 8 bar. Compressed air pressure- 6 bar. R.P.M – Normal 12, starting 7
Stem Line
There are two major steps in stem lineStem Conditioning Stem cutting and dryingAfter drying stem is stored in CRS bins and mixed with the processed lamina for final Tobacco which is again processed through cooler.
STEM CONDITIONING
Feeding Inspection Autofeed
Air LiftSieving
Admoist Stem Bins
STEM CUTTING & DRYING
Discharge from Bins Cutters Search and
Fill
GFP & Weycon
STSSTS
T.C. Dryer Sieve and Tower Classifier CRS Bins
Stem Feeding for conditioning
Issue by Blend operation Unpacking Physical Inspection of Stem Airlift for conveying for conditioning Removal of heavier foreign materials
Stem Conditioning
Dickinson Admoist Stem ConditionerThe machine is used for increasing both moisture and temperature of Stem, whilst achieving complete penetration of conditioning throughout the cross section of length. Stem is conditioned from 11% m.c. to 38 +/- 2% m.c. with temperature range 600 C to 700 C. This makes stem soft and pliable for cutting purpose.
Admoist Consists of:Feed Arrangement, Trough, Chassis, Rotor (rotating paddles with drive), Water sprays, Casing Spray, Conditioning spray, take off
Admoist…Working
Stem is conveyed through the Admoist by the action of a three bladed rotor supported with in a U shaped trough. The Pipe at the center is perforated and supplied with low pressure steam with rotary union. At intervals along the length, atomized water spray are directed at the product from above. Thorough penetration of moisture is achieved by the combined effect of steam percolating from the rotor spray pipe, together with the finely atomized water from above. Good mixing is achieved by means of gentle tumbling action which ensures that fresh faces of all particles are continually being presented to the steam and water sprays.
Trough Length : 4.5 Mtr. Paddle Diameter: 0.9 mtr Angle of inclination : 50
Paddle Rotation : 6.5 RPM Cylinder drive motor : 2.2 KW Stem flow rate : 2000 Kg/hr Moisture : 11% to 40% Steam : Pr: 4 – 10 bar,Cons: 220 Kg/hr max Water : Pr: 3 bar min, Cons: 895 Lt/hr
Admoist…Technical Data
Stem Bins There are 5 bins for conditioned stem. The purpose of bins is to bulk, mix and feed
different grades uniformly to the cutter. Capacity: 2000 Kg at 11% m.c. Stem is taken to a Shuttle or traversing conveyor,
which layers it uniformly inside the bin. 4 doffer (Runs at 80 RPM) in each bin are provided
for thorough mixing and ease of discharge from bins.
Stem Cutting
Machine Used- KORBER Tobacco Cutter:KT 2Transport chains convey tobacco to the mouth piece. The mouth piece holds the stem firmly during cutting process. An adjustable compaction force generated by a pneumatic cylinder to achieve uniform compaction. The Knives on the knife drum (50 inclined) cut the stems. The grinder unit moves to and fro on a sliding mechanism, mounted parallel to the knife drum axis constantly sharpens the 8 knivesThroughput is determined by:a)Knife drum speedb)Mouth piece openingc)Conveyor chain speedVariable is Knife drum speed other drives are speed synchronized.
Steam Cutter…Parameters
Cut Width : 140 CPI Cutting Moisture: 38 +/-2% Cheese Pressure: 50 KN Cheese Height : 100-160 mm
(Constant for particular run) Knife drum speed: (250 to 660)
Steam Treated Stem (STS) STS process is intensive steam treatment method Stem is fed through gas tight Rotary Air Lock Steam is blown to chamber through nozzles It condenses on the stem particle and induces a rise in
temperature to a value approaching the temperature of condensate .
High level of material and heat exchange and the low pressure in free jets leads to sudden vaporization of water present in stem cells and causes expansion
Post Treatment chamber : This consists of a venturi, which causes steam to accelerate. The static pressure of the steam reduces at this point, resulting in further sudden vaporization of water contained in cut stem cells, causes expansion
CRS Drying – TC Dryer Equipment: TC Dryer- LEGG, UK TC stands for tubular construction To reduce moisture of CRS from 40% to desired
level (15% ) PID controllers compare the measured value against
the desired value, if there is a deviation controller sends a signal to PLC to increase or decrease the temperature
Process air is co-axial and is set to provide maximum drying condition.
Cylinder inclination:80, RPM:8 to 10 RPM Throughput rate : 1600 to 2000 Kg/hr Product Temperature: 60 0C to 65 0C
Throughput rate : 1600 to 2000 Kg/hr Moisture Content of outgoing Product : 15-16.5% Product Temperature: 60 0C to 65 0C
CRS Drying…Process Parameters:
Tower Classifier
Principle is winnowing. The lighter particle are picked up by a gentle suction and heavier are dropped down
After classification, the CRS ready for adding back in every respect is air transported to the addback bin.
Addback Bins There are 5 addback bins. These stores CRS Also used for layering of add backs such
as smalls, expanded tobacco etc. Also serves to even out moisture Mixing is done with the set of 3 doffers at
discharge Capacity – 2000 Kg max (each) Bin Discharge speed – Variable to match
lamina operation No min. bulking time restriction
COOLER/FLAVOURING Cylinder
The air is being sucked from the DRF which is connected to the ventilated area at the entry of the cylinder
Ambient air enters the cylinder from the exit ports and absorbs the heat in the tobacco
The vanes in the Cooler helps in the providing all surface area to come in contact with air.
Top flavor are being added in some blends in this cylinder & also mixing CRS & lamina properly.
Cut Tobacco Bins: There are two cut tobacco bins where cut tobacco from flavoring cylinder are being conveyed.
Skip Stacker: Six skip are stacked in one stacker from cut tobacco bins & weighed.
Cut Tobacco Storage : Weighment slip containing the blend, operation number ,date of operation, weight are attached to stacker & store in CTS.
CTS
SECONDARY MANUFACTURING DEPARTMENT
SMD Functions
Receiving Cut Tobacco from CTS and WMS from warehouse
Manufacturing various brands of cigarettes
Packing the cigarettes in CFCs and delivering to Shipping
SMD FLOW LINECut Tobacco
from CTS
Making Machine
Branded Cigarettes
Packing Machine
Cigarette Packets
Outers / CBOs
CFCs
WMS fromWarehouse
Shipping
WMS Waste
Waste Cigarettes
WinnowingsWMS Waste
Waste Cigarettes
WMS Waste area
Reprocessing at PMD
Shaker Feeder
Pneumatic feedTobacco
Brands & Specifications – As per Length of Cig King Size – 84 mm (64 mm Tobacco length and 20 mm filter length)
a) India Kings
b) Wills Classic
c) Gold Flake Kings Longs – 74 mm (Filter = 11 mm)
a) Wills Navy Cut
Regular Size Filters – 69 mm (Filter=11 mm)
a) Gold Flake Filter
b) Gold Flake Premium filter
c) Capstan Filter
d) Bristol Filter
e) Wills Flake Filter
Brands & Specifications …
As per cigarette circumferencea) King Size – 24.75 mm
b) Longs/Junior Size Filters – 24.5 mm
As per pack varietya) Hinge Lid (HL)
b) Round Corner (RC)
c) Pillow Pack (PP)
d) Hinge Lid / Enlarged Pack (HL/EP)
e) Twin Ten (TT)
As per number of cigarettes in a packa) 10 HL (5 on 5)
b) 10 PP (5 on 5)
c) 20RC (7-6-7)
d) 20 TT (Twin Ten)
On the basis of total cigarettes in a Bundlea) 200’s : King Size and Longs (navy cut)
b) 500’s : All regular Size Filter segment
Brands & Specifications …
Production Planning
Monthly Production Plan Logistics Department generates the plan based on HO
marketing plan and STOs from marketing branches.
Three Day Niche Manufacturing Plan: This is based on STOs received and the stock available at
Shipping. This is used by shift managers to plan the production. This Plan is given by Logistics on following days: Wednesday : For Planning of Friday and Saturday Friday : For planning of Sunday, Monday and Tuesday Monday : For Planning of Tuesday, Wednesday and Thursday
Shift Co-ordination
There are a total of 6 Module Resource Managers (MRMs)
3 MRMs comes in shifts- Early, Late and Night, 1 MRM will be in common shift for module nurturing and one will be in early shift for weekly cleaning schedule.
Shift pattern changes every week.
Modules
The entire SMD shop floor has been organized in small groups called “Modules”
Modules are a combination of making machines and packing machines with certain owned resources and certain shared resources.
There are six modules namely – Pragati, Nai Rahein, Vikas, Frontier, Josh and Nav Marg.
Reasons for dividing into modules are:• Easy monitoring and control of each machine• Creates competition among modules which increases efficiency• Creates a sense of ownership in the employees.
Module 1 – Pragati
Making Machine
No MakeCapacity (CPM)
11 Loga 7000
14 Mark8Max
3000
Total Capacity 10000
Packing Machine
No Make Capacity (PPM)
43 GDX2S 300
44 GDX2S 300
45 GDX2S 300
Total Capacity 9000
Module Ownership : Mr. K G Prasad
Cleaning Day: Wednesday
Size Manufactured : 69 mm
Module 2 – Nai Rahein
Making Machine
No Make Capacity (CPM)
9 Mark8Max 3000
25 Mark8Max 3000
3 Mark8Max 3000
Total Capacity 9000
Packing Machine
No Make Capacity (PPM)
33 GDX2NV 350
35 GDX2NV 350
Total Capacity 7000
Module Ownership : Mr. A. Paul
Cleaning Day: Tuesday
Size Manufactured : 74 mm (Wills Navy Cut 10PP)
Module 3 – Vikas
Making Machine
No Make Capacity (CPM)
4 Mark8Max 3000
5 Mark8Max 3000
6 Mark8Max 3000
Total Capacity 9000
Packing Machine
No Make Capacity (PPM)
33 GDX2NV 420
35 GDX2NV 420
Total Capacity (Cig Per Minute)
8400
Module Ownership : Mr. A. Paul
Cleaning Day: Thursday
Size Manufactured : 69 mm
Module 4 – Frontier
Making Machine
No MakeCapacity (CPM)
16 Loga 6500
18 Loga 6500
Total Capacity 13000
Packing Machine
No Make Capacity (PPM)
37 GDX2NV 420
51 Focke 350 300
46 GD X2NV 350
Total Capacity (Cig Per Minute)
13700
Module Ownership : Mr. Sujeet Saha
Cleaning Day: Saturday
Size Manufactured : 84 mm (All King Size segment)
Module 5 – Josh
Making Machine
No MakeCapacity (CPM)
17 MK8 max 3000
15 Loga 7000
Total Capacity 10000
Packing Machine
No Make Capacity (PPM)
39 GDX2S 300
32 GD X300 300
56 Focke 349 300
Total Capacity (Cig Per Minute)
9000
Module Ownership : Mr. Sumit Johri
Cleaning Day: Friday
Size Manufactured : 69 mm
Module 6 – Nav Marg
Making Machine
No Make Capacity (CPM)
1 MK8 max 3000
2 MK8 max 3000
19 MK8 max 3000
23 MK8 max 3000
Total Capacity 12000
Packing Machine
No Make Capacity (PPM)
31 GDX300 300 – EP
38 GDX2S 300 – EP
40 GD X2S 300
60 CME 180 TT
Total Capacity (Cig Per Minute)
12600
Module Ownership : Mr. Narayan
Cleaning Day: Monday
Size Manufactured : 69 mm (TT & EP packs are also packed here)
Making machine types:
M/c make No of m/cs Std Capacity (Cig / Min)
Loga 3D 3 7,000
Loga 2D 1 7,000
MK8 Max 12 3,000
Packing Machine Types
M/c make No of m/cs
Std capacity(pkts / min)
GDX2NV 6 420
GDX2S 7 300
GDX300 1 300
Focke 349 1 300
Focke 350 1 300 (20 Cig per pack)
CME TT 1 180 (20 cig per pack)
WMS Types
WMS is the material found on cigarette packet except tobacco.
Making WMS : Cigarette Paper Printed/Pre printed Cork Tipping Filter Rod Ink Gum
WMS Types…
Packing WMS: Foil Inner Frame Blank Bi-Axially Oriented Poly Propylene (BOPP) Tear off Ribbon (TOR)
Outer WMS: Gay Wrapper, CBO CFC ITC printed tape
Maintenance Budget
Head Office
Projected sale by All Mktg Offices
Target is divided in all units
SaharanPur
GD : 2.50 Rs / M cig
Focke : 2.00 Rs / M cig
Loga : 4.25 Rs / M cig
MK8 : 1.75 Rs / M cig
Total Maintenance budget is calculated by Multiplying Cig target with the per M budget of individual machine
Maintenance Systems
Preventive Maintenance Cleaning of machines three times a day before the start of each shift –
done by machine crew and technician Weekly 4 hours cleaning – Each module is cleaned for 4 hours once
in a week. A different day is fixed for each of the 6 modules. The maintenance team does this job.
One Day Maintenance (ODM) – A maintenance schedule for each machine is prepared for maintenance every 45 days. Maintenance team with specialists does this job.
Break down Maintenance As and when the machine breaks down or when the quality
parameters are not within the tolerance limits, break down maintenance is done.
Different Maintenance Schedule of Makers and Packers:
Maker Weekly Cleaning ODM (after 750 hrs) Quarterly Maint (after
1500 hrs) After 4500 hrs (Earlier
3000 hrs) PPM (after 9000 hrs)
Packer Weekly Cleaning ODM (after 750 hrs) Scheduled Maintenance
of sub assemblies. Deep Maintenance
(After every 3 year)
Short Folder
Long Folder
Tobacco
Hopper
Elevator
Flapper
Magnet
Cleaner
Carded Drums
Picker & Winnower
Suction Chamber
Ledger
Cutter
Air Cell
Ecreteur Discs
ShoeGarniture
Tongue piece
HeaterP.P.A
Printer
Paper
Mk8 Layout
Commercial Department
Department Structure:
Commercial Manager
Asst Commercial
MgrFS-1 FS-2 FS-3
Excise and taxation
Bill Passing, Budget, IVR, Purchase etc.
Budgeting
There are 3 heads under budget: Employee Budget Personal salary and wages Production expenses
Approved by H.O. every year Discussed in Monthly Branch Performance review meetings MOM of BPR meeting are prepared and circulated Outlook : These are the in-between revised figure of budget Conversion Cost : Cost required to convert Raw Material
into finished goods. This cost involves the 3 heads mentioned in first point.
Purchase
All Raw Material is purchased at HO level Other items are purchased at unit level. These are categorized
into : DI (Direct Indent) : Non codified items
• Further divided into Capex and Revenue items SI (Stock Items) : Coded items, being used regularly
Purchase requisition is generated by user department PR series: 50….. for Capex items. 30…. for revenue items Purchase order is signed by two authorities for value >10,000
Rs. (e.g. CM & BE) PO series: 52….DI items, 45….SI items, 51…Capex items
IVR
IVR is known as Inter Business Area Clearance This is used for any kind of transaction within the
same division of ITC or within the different div of ITC companies
SAP is used for clearance within ITD ACCREMON is used for clearances of different
divisions.
HR Department
Department Structure: HR Manager
Asst Manager 1
Asst Manager 2
Asst Manager 3
Welfare Officer
SMD PMD + Canteen
Engg. + Comm.
Welfare activities
Quality Information System
Function of QUIS is to monitor all the quality parameters of Tobacco, Cigarettes and Packets.
MOISTURE TEST
PARTICLE SIZE TEST
FILL VALUE TEST
PMD TESTS
Electric OvenElectronic weighing machineTraysDessicatorTobacco filling tins
Apparatus used
Moisture test is done for both PMD and SMD. In this test the moisture of the tobacco is found out
Moisture Test
• Samples will be collected from PMD/SMD• 20 Containers in one tray & total 5 trays can be loaded once
into oven• Each container will be loaded with 10 gms of tobacco using
weighing machine• Containers are closed with perforated lids to allow escape of
water content due to heat• Oven is pre-heated to come to 1100c• All the five trays are loaded into oven• Oven is put-on for 3.5 Hrs.• Trays are taken out and placed in the dessicator to cool
down for 20 minutes.
Procedure for Moisture Test
9. Dessicator consists of Silica gel at the bottom which absorbs the heat from the surrounding so that tobacco inside container neither gains nor loses moisture
10. Containers are taken out of the dessicator, individually weighed & readings are noted down
11. Loss in weight expressed in terms of % will give us the moisture of tobaccoWt. Of tobacco before heating = Wx in gms
Wt. Of tobacco after heating = Wy in gms
Moisture (in %) = ___
Wx X 100
Wy1 -
Procedure for Moisture Test…
Particle Size Test
Jel Sieve Electronic weighing machine
Apparatus used
This test decides the quality ratio of tobacco. It is basically to find out the degradation level of tobacco which mainly contributes for sensory characteristics of smoke.
1. Collect 50 gms of tobacco sample.2. Put it into top first bin. (should not be overfilled
because more compression will be there and filtration will not take place properly).
3. Close the container firmly & put on the machine to run for 10 min. continuously.
4. The whole container is subjected to eccentric rotation such that the tobacco on the top gets filtered through various meshes depending on their sizes.
5. Containers are taken out & individually measured and weights are noted down.
Procedure for Particle size test
Q.R. (in %) = A + B----------------A + B + C + D
X 100
A – 2.0 mm
B – 1.4 mm
C – 0.85 mm
D - SAND
A = Weight of 2.0 mm Tobacco
B = Weight of 1.4 mm Tobacco
C = Weight of 0.85 mm Tobacco
D = Weight of sand at bottom most
Note:1. QR should not be less than 70 %2. Sand proportion also should not be more than 10 %3. This test does not depends on moisture
6. Quality ratio is calculated as follows:
Particle size Test
Apparatus used
This test is conducted to find-out the Fill value of the tobacco. This mainly depends on the moisture content. This the most important characteristics, which decides the density of filling.
Fill Value Test
Digital Densimeter Electronic Weighing machine
1. Bring the piston to touch the bottom surface of the cylinder in idle condition and set the indicator to ‘0’
2. 20 gms of tobacco is measured & put into the cylinder
3. Piston is made to exact a load of 3 Kg on the tobacco inside cylinder continuously for 30 sec.
4. Reading is noted i.e. the height of tobacco cheese.
5. With relation to height of the tobacco cheese, volume of the cylinder, fill value is calculated at 13.5 % moisture.
Procedure for Fill value test
SMD TESTS
END STABILITY TEST
FIRMNESS TEST
PACK SEALING TEST (PST)
MOISTURE TEST
End Stability Test
End stability tester Electronic Weighing
machine
Apparatus used
This test finds the loose shorts in the cigarettes.
1. Load 50 cigarettes to cage2. Continue above procedure for remaining 3 cages3. Leave 5 mm gap from the wall to allow loose tobacco
collection into the tray on the bottom 4. Start the machine to run continuously for 268 rev. (3 min
with 90 rpm)5. After the machine stops, transfer loose tobacco collected
in the tray to weighing bin 6. Note down the readings and repeat the same for
remaining cages
Procedure for End Stability test
W = Wt of shorts collected
End Stability = (W/50) x 1000 mg/cig
Firmness Test
Auto Hardness Tester
Apparatus used
This test is done to find out firmness of the cigarettes. Conducted for 30 cigs per test in 3 sets (ex. Maker).
1. The circumference of the cig is calculated in QTM and diameter is derived
2. Diameter = mean Circumference / 3.14153. 30 cigs are loaded on to the machine hopper4. Measured dia is entered in the machine (analog
type)5. Machine accepts a batch of 10 cigs & will be pressed
with the load of 2 kg for 30 sec6. Mean contraction dia is displayed and printed out7. Then the firmness is calculated for 13.5% moisture
Procedure for Firmness Test
Pack Sealing Test
PS Tester
Apparatus used
As the moisture content of the tobacco is very important till it reaches the end customer, it is most necessary to ensure proper sealing of the pack such that the tobacco inside neither gains nor loses the moisture. To ensure the same CPST is done.
1. Load 10 cig packs to the machine2. Machine will pick-up one at a time & pierce into
the pack3. Blows the air from the pierced end continuously4. 50mm WG pressure is maintained throughout
the pack5. Amount of air accepted by the pack is the
indication on quality of packing6. Machine gives the printout indicating the
pressure maintained and flow through the pack which is a direct measure of quality of Sealing
Procedure for PST
Outer Pack CigarettesIt is done for visual defects
PQRS is carried out on
Quick PQRS : Done for both maker and packerDetail PQRS : Detailed test done by quality auditors. Done only after packer
Types of PQRS
PQRS
Engineering Stores…
All inventory is kept in Engineering stores, and material is procured and received through Eng Stores.
Inventory Guideline : 0.5 % of Asset Replacement Value
Actual : 5 % (Approx 6.4 Crore) Type of spares:
VB PD DI
Engineering Stores…
VB : These are codified items for which Safety Stock and ROP is defined. These are procured automatically by running MRP.
PD: These are also codified items for which there is no safety stock defined, these are also procured by MRP run, provided purchase requisition is made in advance by user.
DI: These are Direct indent items, these are not codified and procured directly by user, receiving and issue of these items will be done by stores only.
Engineering Stores:
……….. SS1 : SREFCT Vendor SREFCT SSD : SREFCT CES Vendor
SREFCT SCS : SREFCT CES Vendor
CES SREFCT SIM : These are imported items
Engineering Stores…
Returnable Gate Pass: These gate pass are required for those items which are returnable, and are issued by Stores supervisor
There are four copies : White(gate house), Yellow(stores), Green(Vendor), red(Vendor, and received and filed by stores after getting the material back)
Authorization :• For less than 7 days : Authorized managers• For more than 7 days : HOD• For more than 30 days: BM
Boiler House
Boiler is used for generating steam for following application:
• PMD (DCC&C, Admoist, HT, KLD, STS, TC dryer, casing prep, NTM) : This is mainly for tobacco processing.
• Air Washer and VAM• Canteen – For food preparation• Others (F.O. tank, Feed water tank, service
tank etc.)
Boiler House…
There are 4 no. of boilers
*Boiler No. 4 is water tube boiler installed for DG flue gases heat recovery. Capacity = 2.25 Ton
S.No. Boiler No. Working pressure
Tested on Testing due on
1 UP 5535 10.54 24.01.06 18.01.07
2 UP 3503 9.975 19.10.05 10.10.06
3 MYS 1276 10.02 16.02.06 15.02.07
4 UP 5785* 10.5 28.07.05 03.07.06
Boiler House…
Model : WBN-4TPH-PF-44 H/L Make : Nestler Type : 3 Pass, Wet Back Design Fuel Used : Furnace Oil Capacity : 4 Ton each Stack Height : 54.2 Mtr Surface Area : 127 m2
Three pass Wet Back Design Boilers
Three-pass wetback design has a rear water wall,which separates the primary heating surface of the combustion chamber from the rear tube sheet.The water jacket eliminates the need for a refractory wall.The rear water wall eliminates the need for gasketing,which is vulnerable to the temperature generated in the rear of the turnaround area.The fact of the matter is —a wetback design boiler not only overcomes these expensive deficiencies,but it has great overall efficiency and virtually maintenance-free construction.
Boilers.. Fuel Feeding Ckt
1 2 3 8 9P F.O. tank
Cap:50 KL each (5 Nos)
service tank Cap:5 KL each (2 Nos)
Meter
Pump
FilterP
Pumping and Heating. Pr: 20 Kg/cm2, Temp:100-110 0C
Boiler (1,2 and 3)
Boiler… Feed water ckt
Feed Water Tank (cap 15 KL)
DM Plant
Condensate from PMDMetering & Temp
measurement Common Header
Feed Water PumpHead : 107 MtrFlow : 12 m3/hr
Check Valve
Boiler •Magnetic switch to control water level
•Two level indicators are provided for visual
Boiler… Operating Parameters
Oil Temperature : To be maintained at 100-110 0C
Oil Pressure : 20 Kg/cm2 approx. Inlet Water Temperature : 80 0C
(maintained by steam at feed water tank) Air Flow : 15 Kg for 1 Ltr of fuel Oil Consumption : EVR : 13 to 14 (EVR is the steam
generated (in Kg) per Liter of F.O. consumption i.e. Evaporation Ratio
Boilers… Controls and safety
Low Pressure Cut off : It cuts off supply of fuel to one nozzle and reduces the air flow to run boiler at lower output.
High Pressure cut off : It completely shut off the fuel and air to boiler when desired pressure is reached and starts again at the lower limit
Safety Valve : There are two safety valves provided on boiler discharge to blow out the excess steam
Feed Water Level Control : Feed water is controlled with the water level in boiler, help of magnetic switch
Boiler… Efficiency Calculation
Boiler Thermal efficiency can be calculated on the basis of CV
η = Mw (Hs.x–Hw)x100/(Mo x CV)Where:η = Thermal efficiency of boilerMw: Mass of water/steamHs.x: Heat in steamHw: Heat of feed waterMo : Mass of OilCV : Calorific Value of Oil (9600 Kcal/Kc of F.O.)
Boiler… Efficiency Calculation
Boiler efficiency can also be calculated on the basis of losses
η = 100 – Flue gas loss – Hydrogen Loss- radiation loss
= 100 – 0.576 (Tg – Ta)/% of CO2 – (6.5+2)
Where:η = Thermal efficiency of boilerTg= Flue gas temperatureTa=Atmospheric Temperature
Boiler … Maintenance
Preventive Maintenance is followed for Boilers. Two schedule are followed: Monthly : This involves mainly tube cleaning
and regular scheduled maintenance (This is done on every Monday)
Yearly : This is detailed maintenance which is done every year before the inspection of boilers by boiler inspector.
* M/s Thermofab has been allotted the Maintenance contract for boilers
Boilers… Statutory Requirement
Hydraulic Test : Every Boiler must be hydraulically tested every year in presence of Boiler inspector. It is carried out by applying 1¼ times the working pressure of boiler, for the time of 30 min. (testing water temp should be between 20 0C to 50 0C)
Steam Test : Yearly, in presence of inspector, For checking whether safety valves are working at desired pressure to relieve boilers excess steam.
Stack Emission: This must be less than 250 mg/NM3. (This is checked by M/s Envirochem)
Compressors and Boilers – Layout
4
3
2
1
ARDryer
MYS-1276
UP – 3503
UP – 5535
Compressors…
Qty : 4 Vertical Reciprocating compressor Single stage Double Acting Make : Ingersoll Rand Model: 8 x 5 ESV- 1 – NL - 2 Capacity:125 CFM each Motor Rating : 30 KW / 1470 RPM Compressor RPM : 760 RPM
Compressors…
Safety interlocking: There are two safety interlocking provided
for compressor: Low Pressure tripping/interlocking for
lubrication oil. Low pressure tripping/interlocking for cooling
water.Other safety Interlocking required:
Flow Switch for cooling water.High pressure switch for oil.Outlet compressed air temperature monitoring
and interlocking.
Compressors…Statutory Requirement
Following test are required to be performed for compressed air system by competent agency:
Hydraulic Test for Air Vessel : Every Alternate year, by applying 1.5 times the rated pressure of vessel.
Thickness test : For complete pipe line, frequency is every six months.
Air Dryer
Capacity: 400 CFM Designed Pressure : 10.5 Kg/cm2 Actual Pressure : 5-6 Kg/cm2 Make : ITM Projects (Pvt) Ltd Refrigerant Used: Freon (R22) Refrigerant type air dryer : Based on
refrigerant cycle which consists compression, condensation and evaporation of the refrigerant.
Motor Garage
Maintenance of machines is done by motor garage.
Following Machines are available: Fork Lift : Total 11 Nos. (Make: Macneill Eng. Ltd)
• Fork Type: 7• Clamp Type: 3• Wheel rotating attachment : 1
High Reach Truck (Lindey Make)• For Leaf: 3 Nos (2 for issue and 1 for receipt) • For WMS: 3 Nos
BOPT (Battery Operated Pilot Tube)• For Secondary : 6 Nos• For WMS: 1 No.
Tractors: 2 No (Make: Massey Ferguision)
System of PWKC
PWKC is a peti works contract, these are used for works for which any kind of labor/manpower is involved.
There are two kinds of PWKC SI: Service Indent (Only labor is
involved), 53… series WI: Work Indent (Labor and Material
both are involved), 54… series
Requirement of Job
Quotation, first principle costing & negotiation
Raising Purchase Requisition
Preparation of PWKCand attachment of logic note,
Report sheet and CLRA Act check
Signing by BE/PM, CM and BM
Back to EnggHead clerk
for sending tovendor
Service request Form (For starting
work as per PWKC)
Receiving of PWKCAfter completion of
work
PW
KC
Sys
tem
Commands Used for PWKC…
ME51 : For raising PR ME52 : For editing PR ME53 : For over viewing PR ME21 : To raise PWKC against PR ME22 : To edit PWKC ME23 : To over view PWKC ML81 : For Receiving PWKC
P1 P2 P3 P4
P5
P6
P7
P8
P9
DOMESTIC / DRINKING(100 KL)
PROCESS(100 KL)
Sprinkler SumpCap.300 KL.
.
Hydrant SumpCap.328 KL.
Domestic Sump.(200 KL.)
WaterSupply
AutoController
O/HTank
Common Sump. Cap-88 KL
P1-Jocky PumpP2-Hydrant PumpP3-Sprinkler PumpP4-Hydrant EngineP5 & P6-Domestic PumpP7 & P8-Drinking PumpP9-Drain Pump
Tube well No-1.behind TTCTYPE---SubmersibleMake : GrundfossKW/HP----12.5Head-------60 M3/Hrs
Tube well No2 OPP FO TankTYPE---SubmersibleMake : GrundfossKW/HP----12.5Head-------60 M3/Hrs
Tube well No-3 Near UGRTYPE---SubmersibleMake : GrundfossKW/HP----12.5Head-------60 M3/Hrs
Water Distribution
Water Treatment
DM Plant DM water is used mainly for Boilers, it
is used also in small amount in DG water jackets, PMD bins humidification etc.
Softening Plant : Soft water is used for cooling towers,
Compressors cooling, Air Washers
DM Plant
Demineralization, also known as deionization, is the process of removing dissolved minerals from water to make it suitable for industrial uses.
Make ion exchange Capacity : 300 KL per regeneration Daily Monitoring of following parameters:
TDS : <15 pH: 8 to 10 Total hardness : 10 Alkalinity : 5 to 10
DM Plant
Ion Exchange Technology Ion exchange purifies water by filtering it through a tank
containing small beads of synthetic resin. The beads are chemically treated to adsorb either positively charged cations or negatively charged anions, and exchange these ions for hydrogen (H+) or hydroxyl ions (OH-) based on their relative activity compared to the resin. The ion exchange process purifies the water until all available exchange sites are used, at which point the resin is exhausted and must be regenerated by use of chemicals.
HCl : For regeneration of cation resins Caustic Soda Ca(OH)2: For regeneration of anion resins
Softening Plant
A water softener works on the principle of cation or ion exchange in which ions of the hardness minerals are exchanged for sodium or potassium ions, effectively reducing the concentration of hardness minerals to tolerable levels.
Ion exchange method is used for water softening. This unit uses sodium chloride (table salt) to recharge beads made of ion exchange resin that exchange hardness minerals for sodium.
ETP
Aeration TankSedimentation
Tank
Sludge Tank
Discharge Water TankFF
Cl
TankFor gardening
Alum
V-Notch
Storm Water tank
Sewage Water tank
Blower Blower
ETP…
Aeration Tank: • This tank contains Bacteria and air is supplied to the
bacteria inside the tank with the help of blowers• Urea and Di Ammonium Phosphate are used as a nutrition
of bacteria Sedimentation tank:
• Overflow of Aeration tank goes to sedimentation tank• Alum is dosed into sedimentation tank, Alum reacts and
settles down the suspended solids Discharge water and Sludge tank:
• Overflow of sedimentation tank goes to discharge water tank and settled solids goes to sludge tank
• From discharge tank water is pumped through Multigrade sand filters to separate tank
• Water is pumped in another tank and sent for irrigation purpose
ETP Parameters
Discharge : 200 to 250 KL per dayParameter Value Monitoring
Actual Required
pH 7.0 5.5 –9.0 Hourly
TDS 500-700 <2100 Every Shift
TSS 40 <100 Every Shift
TS 600-700 <2200 Every Shift
COD 70-100 <250 Weekly
BOD 15-20 <30 Weekly
MLSS 250 - 400
Air Washers
Air Washer:• Tobacco m.c. is 13.5% which is stored in CTS and
filled in cigarette at SMD. Tobacco is a moisture sensitive product
• It is experimented and practiced that at 25 0C and 65% RH moisture equilibrium is maintained for tobacco
• Air washers are required to maintain the condition of air at CTS and SMD as per requirement
AHU: Air Handling Unit• Temperature is required to maintained in office
areas at certain level in summer for cooling purpose.• AHU’s are installed which cools the air in the
summer in office areas
Air Washer
There are total 4 Air washers for conditioning SMD floor(Two above CTS and two above shipping area). Capacity of each air washer is 127 TR
There are total two Air washers for CTS floor which are located above CTS floor. Capacity of each is 45 TR
There are total 7 AHU (4 for Admin block, 2 for SMD offices and 1 at WMS
Air Washer…
Return Air Filter, Damper Fan and Motor: Draws air from the conditioned place
Exit Air Damper: To take the air out as per desired qty Fresh air filter and damper: Fresh air is sucked inside the
system with supply air fan suction Preheating coil: In winter air passes through preheating
coil, sensible heat is increased Air Distribution plate: To achieve uniform distribution
throughout the spray chamber, for good contact between air and water
Water spray: Water required is sucked from tank and sprayed to with the help of nozzles
Water Eliminator: PVC make bend plates, these changes the direction of air flow and remove the free water held in suspension and also facilitate deposition of the dist on the eliminator plate
Air Washer…
Water Eliminator: PVC make bend plates, these changes the direction of air flow and remove the free water held in suspension and also facilitate deposition of the dist on the eliminator plate
Cooling Coil: Air looses sensible heat when passes through the cooling coil
Reheating coil: (For winter) For increasing the sensible heat of air, it is passed through reheating coil
Supply Air Fan: These fans are drawing the processed air and passes it to the supply air fan room where it goes through the duct to conditioning zone
Supply air damper: Provided to regulate the air quantity which is delivered to conditioned zone
Chillers
Chilled water is required for Air Washer as well as Air Handling Units in summer
Chillers are used to make water chilled
There are two chillers:• Screw Chiller (Refrigeration cycle): 390 TR• VAM (Vapor Absorption Machine) : 600 TR
Power House
There are 5 Generators in Power House Fuel Used : HSD
1 2 3 4 5
Make: CumminsGeneration Capacity: 1000 KVA
Make: MTUCap: 1670 KVA
RUPS
Rotary UPS
Requirement : To handle interruption of Grid power supply.
Time required: 12 seconds Capacity: 1670 KVA Power Bridge stores the Kinetic
Energy by running of Flywheel at 3400 RPM
Rotary UPS…
M/G
DGPower Bridge (Flywheel)
Rectifier
DG No.5 Make:MTU
Clutch
Grid Supply
Supply to critical loads
Breaker
Mechanical energy remains stored in flywheel during grid power supply, which acts as a power source at the time of power failure for the time period required for DG to start and take the load.
Fire Protection systems…
FIRE
Hea
t
Oxygen
Com
bustible Material
Fire can be controlled by eliminating any of the cause mentioned above i.e. Heat, Oxygen or Combustible Material that can be done by Cooling, Smoothing and Starvation respectively
Fire Protection System…
Following Fire Protection systems are used at different location inside factory:
• Fire Extinguisher• Fire Hydrant• Foam Trolley• Water Cum Foam Monitor Trolley• Sprinklers• Fire Hose reel drums (installation process)
Fire Protection System…
Fire Extinguisher:• Water Type : Used for only A type of fire.• Foam Type : Can be used for A and B type
of fire. More suitable for Fuel.• DCP Type : Can be used for B and C type of
fire. • CO2 Type: Used for B and C type of fire.
More suitable for electrical panels and electronic items
Fire Protection System…
Fire Hydrant : Fire hydrant consists of pressurized pipe line and 60 points to operate the same. This system will always be pressurized with the help of pump located at UGR.
Hose reel Drums: These are hose reel with nozzle for accessing the points which are not easily covered with the Hydrant hose and nozzle. These points are connected with the hydrant line.
Foam Trolley : Four foam trolleys are provided at Boiler house, Power House, waste oil storage and flavor room. These can be connected to hydrant points for operation. Capacity is 100 Ltr of foam in each trolley.
Fire Protection System…
Water Cum Foam Monitor Trolley: These trolley does not contain foam. Foam is supplied externally, which is stored in separate containers of 30 Ltr each. These can be used for big fires as per the availability of foam.
Sprinklers : Sprinklers are water suppression as well as detection system as it suppresses the fire and displays the location of fire at gate house.
Fire Protection System…
Fire Detection Systems: Smoke Detectors Heat Detectors Beam Detectors Sprinklers
Alarming System: MCP (Manual Call Points) Public Address system (Strobe hooters are
installed now with flashing system) Danger Siren for evacuation Portable Hand Siren Emergency Phone No. 241
Fire Protection System…
Breathing Apparatus: Consists of Compressed Air Cylinder at 300
bar, Pressure gauge and Lungs demand valve
Its capacity is 30 min, and an alarm is generated when pressure in cylinder falls below 50 bar.
Smoke Hood It covers the face and filters the smoke
mixed with air for breathing. It can operate upto 10 to 15 minutes. This
used once can not be used again.
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