1. The British American Tobacco
Engineering Internship
(GLT-Plant)
Name Haziq Bin Imran
Year 4rd
Year
University Wah Engineering College (WEC)
Date of Submission
27th
August, 2015
Pakistan Tobacco Company Limited- Akora Khattak Factory
P.O Nowshera 24100
District Nowshera

2. REPORT TITLE
Quality Improvements & Down Time Reduction of GLT Plant.
Submitted To
Sir Ahmer Rias (GLT Shift Manager)
Submitted By
Haziq Bin Imran WEC, Wah Cantt
Date of Submission
27th
August, 2015
DEPARTMENT OF MECHANICAL ENGINEERING
Pakistan Tobacco Company Limited-Akora Khattak Facory
P.O Nowshera 24100
District Nowshera

3. Table of Contents
SR # PROJECT TITLE PAGE #
1 Propositions and conclusions of Packing Area of Small
Lamina (SL) & Stem
4-6
2 To Study the problems and their solutions in the
Quality Process of Line 1.
7-10
3 Identification of Spillage Conveyors its Reformative
Measures.
11-13

4. 4
PROJECT#1
Propositions and conclusions of packing Area of small Lamina (SL) & stem
Objective
The Project aims to study the processes involved in the packing of Small lamina
and Stem and to figure out the problems that reduces the overall efficiency,
increased SL rejections and greater lead times.
Packing
 Stem
 Small lamina
Stem Packing Section
Following are the problems that were encountered during the process of stem
packing.
 Heaps of Stem around the area
 Less lay-man than required for better execution.
 Labour Seems less committed because of High Temperature at work area.
Conclusions & executions
 As each bag of stem is to be weighed 51 kg so the filler man should fill more
than 45 kg more less so that the weighing person only adds the desired
kilograms from the surplus trolley, In this way one does ‘not throw the stem
on the floor and avoids stocking at floor that needs extra time to be stored
and looks not messy.
Problem Status: executed

5. 5
 When the feed rate of stem goes high then practically there should be
sufficient labor to control the filling of bags to avoid heaps of stem on floor
and reduced lead times.
Problem Status: Executed.
 If extra heavy duty blowers are installed at appropriate positons then the
heating & high temperature problem can be reduced for the workers to duty
efficiently.
Updating Status: Pending.
Small Lamina (SL) Packing Section
Small Lamina packing is a critical area as it involves the separation, classification,
screwing drying and of all the marks of SL i.e. 86, 63, 36, and 60.
Following are the problems that were pointed out during the packing of all grades
of SL.
 Main Fan Suction (CFM) speed was higher than required that was also
sucking the not required SL Bits along with the 86 Mark grade resulting the
SL bits to be greater than 0.4 % in weight and outcomes the rejection from
SL labs.
 Cleaning Issues of Screen drum and Air lock causing mesh choking and
blockage problems.
 Sand and Silica exceeding the advised % i.e. 7.5 in 36 Grade (Lab Results)
 Worn-out Air Drums of Air lock in the Tower Separator.
Conclusions & Executions
 Adjusted Fan Suction (CFM) speed with the help of Fyaz Hassan (Operator)
dated 6.8.2015 to avoid the bits to mix with small lamina ensuring good
quality.
Problem Status: executed

6. 6
 The brushes of the air lock of the screens of the separators are dusty causing
the blockage and choking and proper cleaning if done the issue can never
occur.
Problem Status: executed
 The drums of the air lock were found worn out causing sufficient leakage in
the pressure and temperature and The Lamina was also being sucked with
the SL that results in ruining the quality. They have been replaced.
Problem Status: Executed.
Lab Results (Dated 6.8.2015)
Total Stem Content
After making necessary measures and controlling the speed of fan a sample
of Mark #86 weighing 1000 grams was taken to the lab for testing and the
results were acceptable
The total stem content came out to be 0.06 %
Total Sand and Silica in 36 Mark
As this mark comes from the extraction of mark 63 so care was taken
keeping the screen to be clean of sieving machine so that the sand & silica
may not exceed 7.5 %.
Out of 1000 grams of 36 mark and performing necessary test the results
came out to be 4.5 % which is acceptable.

7. 7
PROJECT #2
To Study the problems and their solutions in the quality process of Line 1.
Objective
The project aims to study in detail the problems encountered in keeping the quality
of lamina of Line 1 and to figure out the causes of decreased efficiency and the
remedial steps to better the standard production and lessen the scrap.
Factors decreasing the quality:
Following are the factors that are responsible for the low quality rates of lamina of
Line 1.
1. Jamming
2. Degradation
3. NTRN
4. Moisture Issues
Quality Figures
Below are the figures that I experienced on 12.8.2015.
Set point: 70
Actual Results
Serial no Time Lab Results
1 9:20 69
2 9.35 68
3 10.20 67
4 11:00 68.4
5 12:38 68.12

8. 8
A. Jamming:
Jamming is a very crucial problem that results in major break down and losses of
leaf quality.
Below are the Jamming issues that I experienced on 12.8.2015.
 Three consecutive jamming at Multi-Separator Classifier no#1
Cause &Conclusions: It was found that the bulk lamina was being
compressed/forced through a confined wedge against the downstream winnower
due to excessive feed rate causing the system to get jammed. Adequate feed rate
with surveillance can avoid this problem.
B. Degradation:
Degradation is a critical problem as it effects the quality badly. Producing more
scrap and less efficient lamina.
Below are the issues that I experienced on 12.8.2015.
 The blend that was being processed had a serial no: APKDAC
 It is a black long thin leaf and has more scrap issues over the years.
 Lab results concluded that the degradation occurs more before the dryer than
after the dryer.
Causes & Conclusions:
Controlling moisture at 2nd
CC before dryer to ensure adequate value i.e. 20.5 +- 5.
By monitoring the moisture we can reduce the scrap that can be produced in the
dryer process due to drying action.

9. 9
C. Not Tobacco Required Material (NTRM):
NTRN holds major importance in increasing or decreasing the quality and presence
of a single NTRN case can lead to rejection of 21 cases.
Below are the NTRN problem that I experienced on 12.8.2015.
 NTRN ratio particularly threads and ropes were high in the GLT factory.
Causes & Conclusions:
Proper care to be taken and repeated training of searchers at the GLT factory.
D. Moisture Issues:
Moisture is checked by an infra lab machine in the laboratory of GLT.
Below are the Moisture results and their problem that I experienced on 12.8.2015.
In the lab.
 The moisture was not properly controlled or monitored from the 2nd
Conditioning cylinder.
The moisture results of the 2nd
conditioning cylinder and after dryer are as
follow.
2nd
Conditioning Cylinder
Specimen Time Moisture Results
TM LAB
1 6:48 19.40 19.19
2 7:52 19.21 19.18
3 10:4 20.24 20.29

10. 10
After Dryer
Specimen Time Moisture Results
1 9:20 13.04
2 9.35 13.11
3 10.20 13.08
 Stem Tester results were even not acceptable.
Specimen Time Stem Weight
(2.3)
1 10:08 2.28
2 10:37 2.47
3 11:07 2.41
4 12:34 2.49
Causes & Conclusions:
The moisture should be controlled after and before the dryer to ensure proper
quality. I believe that the stem results are out of range because of excessive air
blowing in the classifiers of T fan, as it lead to go the stem with the light lamina on
to the vibrator and then to the dryer.

11. 11
PROJECT#3
Identification of spillage conveyors its reformative measures.
Objective
The project aims to identify the conveyors from end to end analysis of Line 1 &
Line 2, causing over throw of lamina and discovering the root cause, also
concluding the necessary measures regarding maintenance.
Note: The task is to consider the spillage of Lamina size greater than 0.5 inch and
not to cater about the dust and soil particles.
A. Conveyors of Line 1
Below are the conveyors of Line 1 with their code number.
Serial No Conveyor No Conveyor Name
1 M304 Inclined Conveyor
2 M304-A Cylinder Infeed Conveyor
3 B-15 Multi-Sep Infeed Conveyor
4 MD-11 Multi-Sep Apron
5 H-15 Common Lamina Conveyor

12. 12
Conclusions (Line 1)
1) The Side Flaps of all most all the conveyor belt to be replaced because with
them being worn out and misaligned, the fresh lamina penetrates through the
driving rollers down on-to the cover.
2) The M304-A Cylinder Infeed does not have any side flaps and that causes a
lot of lamina to run away. More over its lower cover is also open due to a
maintenance issue that is causing dust pollution.
3) The B-15 Multi-Sep Infeed conveyor also do not have any side flap.
4) A considerable amount of lamina spills between the secondary winnower the
MD-11 Multi-Sep apron.
5) The common H-15 Lamina Conveyor‘s side steel flaps to be replaced.
6) The tattered and well-worn of flaps is mainly due to the heat deformation
because with the steel, attached there is a rubber material that goes
plastically deformed.
7) This deformation causes the rubber material to intake lamina on the lower
cover and its goes wasted.
8) The lower cover of conveyors when gets over loaded with lamina causes
stresses on the rollers and makes it vulnerable to break.
Cleaning Plan (Line 1)
9) The conveyor’s lower shield to be cleaned in every 3rd
evening shift.
10) The flaps of the conveyor to be checked on every Sunday.
11) The Conveyors belt to be dusted off and cleaned every evening shift
to avoid any lumps to grow.

13. 13
B. Conveyors of Line 2
Below are the conveyors of Line 2 with their code number.
Serial No Conveyor No Conveyor Name
1 M2 GLT Feeding Conveyor
2 M911 Lamina Conveyor Part (i)
3 M523 Lamina Conveyor Part (ii)
Conclusions (Line 2)
1) The GLT feeding conveyor has a considerable clearance in it and the lamina
leaks of through the wall on to the ground and that place should be filled to
avoid run over.
2) M523 Lamina Conveyor has open side flaps in front of thresher’s line. An
issue that has been repeatedly seen.
Cleaning Plan (Line 1)
3) The flaps of the conveyor to be checked and fixed on every maintenance
day.
4) The Conveyors belt to be dusted off and cleaned every evening shift to avoid
any lumps to grow.