1. Sections of EHS
Safety Guideline for Corporate, divisional
and internal audits are divided into six
sections:
1. EHS Organization and Management
2. Occupational Health and Hygiene
3. Electrical, Mechanical, Buildings, Housekeeping
and safe work practices
4. Fire Protection and Life Safety
5. Environment
6. Accident Reporting, investigation and Control
All the safety systems and rules are covered in
detail in these sections with clear guideline.
2. 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
3. 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.
4. 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.
7. 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
8. 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
9. 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
10. Stacking Procedure
Stacking – As per put-away list CFCs are stacked in the
respective cells.
Example :-
Q / 28 / 2
Row Position Stack
11. 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
12. 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
13. 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
14. 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
15. 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.
16. 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
17. Lamina Line
There are two major steps in Lamina
line
Lamina Conditioning
Lamina cutting and drying
After drying Lamina is mixed with the
CRS stored in addback bins for final
CT which is again processed through
cooler.
19. LAMINA CUTTING AND DRYING
Discharge
from Bins
Air Lift Sieve
Complex
Cutters
Search &
Fill
GFP
Weycon
KLD Dryer Cooling and
flavoring
Cut Tobacco
Bins
Skip Filling and
weighment
CTS
By Pass Cutters
CRS from Bins
20. 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
21. Lamina Feeding
Following 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
22. 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.
23. 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…
24. 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.
25. Principle
The addition of moisture in DCC&C happens due to
Condensation
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 0
C 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
26. 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 0
C in, 75 0
C out
Drive: 11 Kw 1400 RPM
PA fan Drive: 11 Kw 100 RPM
PA fan capacity : 5000 cfm max.
27. 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
28. Casing
Casing 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.
29. Lamina Bins
Purpose 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.
31. Sieve Complex
Sieve complex
Classification 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
32. 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
33. 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…
34. 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 Con
Operating principles : It weighs & measures the
moisture contents of in coming tobacco & feeds the
data to PLC for downstream operations.
Search & Fill
35. 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 0
C.
36. 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.
37. K L D - Dryer
Major 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.
38. K L D
Process parameters :
Inlet mass flow- 6815 kg/ hr.
Outlet mass flow- 5825 kg/ hr.
Inlet temperature- 85o
c.
Outlet temperature- 60 to 65o
c.
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
39. Stem Line
There are two major steps in stem
line
Stem Conditioning
Stem cutting and drying
After drying stem is stored in CRS
bins and mixed with the processed
lamina for final Tobacco which is again
processed through cooler.
41. STEM CUTTING & DRYING
Discharge
from Bins Cutters
Search and
Fill
GFP &
Weycon
STSSTS
T.C. Dryer Sieve and
Tower Classifier
CRS Bins
42. Stem Feeding for conditioning
Issue by Blend operation
Unpacking
Physical Inspection of Stem
Airlift for conveying for conditioning
Removal of heavier foreign materials
43. Stem Conditioning
Dickinson Admoist Stem Conditioner
The 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
44. 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.
45. 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
46. 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.
47. Stem Cutting
Machine Used- KORBER Tobacco Cutter:KT 2
Transport 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 knives
Throughput is determined by:
a)Knife drum speed
b)Mouth piece opening
c)Conveyor chain speed
Variable is Knife drum speed other drives are speed
synchronized.
49. 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
50. 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 0
C to 65 0
C
51. Throughput rate : 1600 to 2000 Kg/hr
Moisture Content of outgoing Product : 15-16.5%
Product Temperature: 60 0
C to 65 0
C
CRS Drying…
Process Parameters:
52. 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.
53. 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
54. 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.
55. 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
57. 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
58. SMD FLOW LINE
Cut Tobacco
from CTS
Making Machine
Branded Cigarettes
Packing Machine
Cigarette Packets
Outers / CBOs
CFCs
WMS from
Warehouse
Shipping
WMS Waste
Waste Cigarettes
Winnowings
WMS Waste
Waste
Cigarettes
WMS Waste area
Reprocessing
at PMD
Shaker Feeder
Pneumatic feed
Tobacco
59. 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
60. Brands & Specifications …
As per cigarette circumference
a) King Size – 24.75 mm
b) Longs/Junior Size Filters – 24.5 mm
As per pack variety
a) Hinge Lid (HL)
b) Round Corner (RC)
c) Pillow Pack (PP)
d) Hinge Lid / Enlarged Pack (HL/EP)
e) Twin Ten (TT)
61. As per number of cigarettes in a pack
a) 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 Bundle
a) 200’s : King Size and Longs (navy cut)
b) 500’s : All regular Size Filter segment
Brands & Specifications …
62. 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
63. 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.
64. 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.
65. Module 1 – Pragati
Making Machine
No Make
Capacity
(CPM)
11 Loga 7000
14 Mark8
Max
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
66. 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)
67. 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
68. Module 4 – Frontier
Making Machine
No Make
Capacity
(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)
69. Module 5 – Josh
Making Machine
No Make
Capacity
(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
70. 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)
71. 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
72. 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)
73. 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
75. 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
76. 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.
77. 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)
80. 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.
81. 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
82. 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.
86. Electric Oven
Electronic weighing machine
Trays
Dessicator
Tobacco 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
87. • 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
88. 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 tobacco
Wt. Of tobacco before heating = Wx in gms
Wt. Of tobacco after heating = Wy in gms
Moisture (in %) =
___
Wx
X 100
Wy
1 -
Procedure for Moisture Test…
89. 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.
90. 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
91. 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
92. 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
93. 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
95. End Stability
Test
End stability tester
Electronic Weighing
machine
Apparatus used
This test finds the loose shorts in the cigarettes.
96. 1. Load 50 cigarettes to cage
2. Continue above procedure for remaining 3 cages
3. 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
97. 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).
98. 1. The circumference of the cig is calculated in QTM
and diameter is derived
2. Diameter = mean Circumference / 3.1415
3. 30 cigs are loaded on to the machine hopper
4. 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 sec
6. Mean contraction dia is displayed and printed out
7. Then the firmness is calculated for 13.5% moisture
Procedure for Firmness Test
99. 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.
100. 1. Load 10 cig packs to the machine
2. Machine will pick-up one at a time & pierce into
the pack
3. Blows the air from the pierced end continuously
4. 50mm WG pressure is maintained throughout
the pack
5. Amount of air accepted by the pack is the
indication on quality of packing
6. 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
101. Outer
Pack
Cigarettes
It is done for visual defects
PQRS is carried out on
Quick PQRS : Done for both maker and packer
Detail PQRS : Detailed test done by quality auditors.
Done only after packer
Types of PQRS
PQRS
102. 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
103. 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.
104. Engineering Stores:
………..
SS1 : SREFCT Vendor SREFCT
SSD : SREFCT CES Vendor
SREFCT
SCS : SREFCT CES Vendor
CES SREFCT
SIM : These are imported items
105. 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
106. 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.)
107. 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
108. 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
109. 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.
110. Boilers.. Fuel Feeding Ckt
1 2 3 8 9
P F.O. tank
Cap:50 KL
each (5 Nos)
service tank
Cap:5 KL
each (2 Nos)
Meter
Pump
Filter
P
Pumping and Heating. Pr: 20
Kg/cm2, Temp:100-110 0
C
Boiler (1,2 and 3)
111. Boiler… Feed water ckt
Feed Water Tank
(cap 15 KL)
DM Plant
Condensate from PMD
Metering & Temp
measurement Common Header
Feed Water Pump
Head : 107 Mtr
Flow : 12 m3/hr
Check Valve
Boiler •Magnetic switch to control water level
•Two level indicators are provided for visual
112. Boiler… Operating Parameters
Oil Temperature : To be maintained at
100-110 0
C
Oil Pressure : 20 Kg/cm2
approx.
Inlet Water Temperature : 80 0
C
(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
113. 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
114. 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 boiler
Mw: Mass of water/steam
Hs.x: Heat in steam
Hw: Heat of feed water
Mo : Mass of Oil
CV : Calorific Value of Oil (9600 Kcal/Kc of F.O.)
115. 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 boiler
Tg= Flue gas temperature
Ta=Atmospheric Temperature
116. 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
117. 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 0
C to 50 0
C)
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)
120. 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.
121. 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.
122. 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.
123. 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)
124. 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
125. Requirement of Job
Quotation, first
principle costing & negotiation
Raising Purchase
Requisition
Preparation of PWKC
and attachment of logic note,
Report sheet and CLRA Act check
Signing by BE/PM, CM and BM
Back to Engg
Head clerk
for sending to
vendor
Service request
Form (For starting
work as per PWKC)
Receiving of PWKC
After completion of
work
PWKCSystem
126. 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
127. P1 P2 P3 P4
P5
P6
P7
P8
P9
DOMESTIC /
DRINKING
(100 KL)
PROCESS
(100 KL)
Sprinkler Sump
Cap.300 KL.
.
Hydrant Sump
Cap.328 KL.
Domestic Sump.
(200 KL.)
Water
Supply
Auto
Controller
O/H
Tank
Common Sump.
Cap-88 KL
P1-Jocky Pump
P2-Hydrant Pump
P3-Sprinkler Pump
P4-Hydrant Engine
P5 & P6-Domestic
Pump
P7 & P8-Drinking
Pump
P9-Drain Pump
Tube well No-1.behind
TTC
TYPE---Submersible
Make : Grundfoss
KW/HP----12.5
Head-------60 M3/Hrs
Tube well No2 OPP FO
Tank
TYPE---Submersible
Make : Grundfoss
KW/HP----12.5
Head-------60 M3/Hrs
Tube well No-3 Near
UGR
TYPE---Submersible
Make : Grundfoss
KW/HP----12.5
Head-------60 M3/Hrs
Water Distribution
128. 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
129. 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
130. 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
131. 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.
133. 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
134. ETP Parameters
Discharge : 200 to 250 KL per day
Parameter 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
135. 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 0
C 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
136. 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
137. 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
138. 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
139. 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
140. Power House
There are 5 Generators in Power House
Fuel Used : HSD
1 2 3 4 5
Make: Cummins
Generation Capacity: 1000 KVA
Make: MTU
Cap: 1670 KVA
R
U
P
S
141. 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
142. 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.
144. 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)
145. 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
146. 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.
147. 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.
148. 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
149. 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.
