An OJT Report On 3 Month Internship at Surya Nepal

I
TRIBHUVAN UNIVERSITY
INSTITUTE OF ENGINEERING
THAPATHALI CAMPUS
An OJT Report On Three Month Internship At Surya Nepal Pvt. Ltd.
By
Bikram Dahal
067-BIE-10
AN OJT REPORT
SUBMITTED TO THE DEPARTMENT OF INDUSTRAIL ENGINEERING
IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE
DEGREE OF BACHELOR IN INDUSTRIAL ENGINEERING
DEPARTMENT OF INDUSTRIAL ENGINEERING
KATHMANDU, NEPAL
SEPTEMBER 18, 2014

An OJT Report on Three Month Internship at Surya Nepal Pvt. Ltd.
II
COPYRIGHT
The author has agreed that the library, Department of Industrial Engineering, Thapathali Campus, Institute of Engineering may make this report freely available for inspection. Moreover, the author has agreed that permission for extensive copying of this project report for scholarly purpose may be granted by the professor(s) who supervised the project work recorded herein or, in their absence, by the Head of the Department wherein the project report was done. It is understood that the recognition will be given to the author of this report and to the Department of Industrial Engineering, Thapathali Campus, Institute of Engineering in any use of the material of this project report. Copying or publication or the other use of this report for financial gain without approval of the Department of Industrial Engineering, Thapathali Campus, Institute of Engineering and author’s written permission is prohibited. Request for permission to copy or to make any other use of the material in this report in whole or in part should be addressed to:
Head
Department of Industrial Engineering
Thapathali Campus, Institute of Engineering
Thapathali, Kathmandu
Nepal

III
TRIBHUVAN UNIVERSITY
INSTITUTE OF ENGINEERING
THAPATHALI CAMPUS
DEPARTMENT OF INDUSTRIAL ENGINEERING
The undersigned certify that they have read, and recommended to the Institute of Engineering. For acceptance, a OJT report entitled “An OJT Report On Three Month Internship At Surya Nepal Pvt. Ltd." submitted by Bikram Dahal in partial fulfillment of the requirements for the degree of Bachelor in Industrial Engineering.
__________________________________________________
External Examiner,…..………………………………….. …………….…………………………. ……….…………………………......
__________________________________________________
Internal Examiner,……….………………………………… …………….…………………………. ……….…………………………......
__________________________________________________
Er. Sailendra Khanal
Head of Department
Department of Industrial Engineering
Date: September 18, 2014

IV
DECLARATION
I hereby declare that I carried out OJT reported in this report in Surya Nepal Pvt. Ltd., Simara, Bara under the supervision of Mr. Ayush Raj Aryal, I/C PMD. I solemnly declare that to the best of our knowledge, no part of this report has been submitted here or elsewhere in a previous application for award of a degree. All sources of knowledge used have been duly acknowledged.
………………………………………..
Bikram Dahal

V
Letter of Completion

VI
EXECUTIVE SUMMARY
Success of industries dependent on questioning the underlying premises associated with basic issues and problems in the areas of quality, productivity, timeliness, flexibility, responsiveness to customers, optimization, research, data analysis for pattern, and cost minimization rather than focusing only on tools and techniques.
Analysis of data help to identify problems and find pattern in problem, so that a model can be develop to solve that problem. Data collection and analysis also helps to create benchmark for future reference.
Solving engineering issues and manufacturing problem is one of the most important task of engineer. Finding the cause and implementing best possible suggestion so as to increase quality and quantity is primary goal of engineering.
Challenging economic conditions and tough competition make production errors and waste unacceptable. Therefore it is necessary maximize output without violating some constraint. Optimization of layout on production floor and inter-operational change time is important, so as to maximum utilization of resources and reduce ideal time along with improvement in quality.
As an industrial engineering student project related to research and data analysis, problem solving and optimization were carried out during my OJT and successful completed. Under research and data analysis projects, filling value of Surya was increased by 3 percent, Admoist protocol was passed and Cp and Cpk of CRS dryer was calculated. Under problem solving, spillage at CTS area was reduce by 5-8 kg/ day, uniform feed was maintained at CRS cutter, and two design were made. Under optimization project, blend change time was optimized.

VII
ACKNOWLEDGMENT
Foremost, I would like to thank The Department of Industrial Engineering (DoIE), IOE, Thapathali Campus for including such opportunities in the BIE syllabus. Especially, I am indebted to Er. Sudan Neupane, DHOD (DOIE) whose continuous effort always guided me.
I express my gratefulness to Surya Nepal Pvt. Ltd, Simara, Bara for giving me suchgreat opportunity of doing on job training.
I would like to express my deep gratitude towards Suresh Kaji Shrestha, Factory Engineer, Surya Nepal, Simara, for selecting me for the training at SNPL.
I would like to express an earnest thankfulness to my project guide Mr. Ayush Raj Aryal, I/C PMD, for his guidance throughout the project. Similarly appreciation to Mr. Sarabjit Rana, Production Manager, and Mr. Dinesh K.C., SMD IC, will always be a due for his valuable instruction and guidance.
I would also like to extend my thank you to Mr. Sarbin Shrestha, Welfare Officer, for his suggestions and help in all possible ways during internship period.
Last but not least, I would also like to thank all the operators, staffs of PMD and QUAS, for their cooperative and helpfulness attitude during my training.

VIII
TABLE OF CONTENTS
Copyright ............................................................................................................................... II
Approval Page ……………………………….………………………………………………………………..……III
Declaration .................................................................................................................IV
Letter Of Completion ..................................................................................................V
Executive Summary ....................................................................................................VI
Acknowledgment ....................................................................................................VII
Table Of Contents ....................................................................................................VIII
List Of Figures .............................................................................................................. X
List Of Tables .............................................................................................................. XI
Abbreviation.............................................................................................................. XII
CHAPTER 1. INTRODUCTION .............................................................................................. 1
1.1 Company profile ..................................................................................................... 1 Introduction ................................................................................................... 1
Portfolio of Business ...................................................................................... 1
SNPL Logo ....................................................................................................... 2
1.2 Vision and Values ................................................................................................... 3
1.3 Policies and Philosophy .......................................................................................... 5 Environmental Policies ................................................................................... 5
1.2.2 Energy Policy .................................................................................................. 5
1.2.3 EHS Policies .................................................................................................... 6
1.2.4 Quality Policy ................................................................................................. 7
1.2.5 Social Accountability Policy ............................................................................ 7
1.4 Major Department in SNPL .................................................................................... 8 Primary Manufacturing Department ............................................................. 8
Secondary Manufacturing Department ......................................................... 9
QUAS ............................................................................................................ 10
Slitting Complex ........................................................................................... 12
Filter manufacturing department ................................................................ 12
1.5 Products of SNPL .................................................................................................. 13
CHAPTER 2. PROJECT AREA INTRODUCTION ................................................................... 14
2.1 PMD ...................................................................................................................... 14 Lamina processing is describe as below ...................................................... 14
CRS Processing line is described as below ................................................... 18

IX
CHAPTER 3. PROJECTS ..................................................................................................... 21
3.1 Research and Data Analysis ................................................................................. 21 Admoist Protocol Test .................................................................................. 21
Increase the filling value of Surya Tobacco .................................................. 28
Cp & Cpk of CRS dryer .................................................................................... 40
3.2 Problem solving .................................................................................................... 44 Maintenance of Feed gap at CRS cutter CFP ............................................... 44
Wastage reduction at product bin ............................................................... 47
Design of pan for HT sampling and stand for Serrico trap ........................... 50
3.3 Optimization ........................................................................................................ 51 Optimization of blend change time of CRS line ........................................... 51
CHAPTER 4. CONCLUSION ................................................................................................ 54
REFERENCES ............................................................................................................ 55
GLOSSARY ............................................................................................................................ 59
Appendix 1 .......................................................................................................................... 67
Appendix 2 .......................................................................................................................... 68
Appendix 3 .......................................................................................................................... 69
Appendix 4 .......................................................................................................................... 70
Appendix 5 .......................................................................................................................... 71
Appendix 6 .......................................................................................................................... 72
Appendix 7 .......................................................................................................................... 73
Appendix 8 .......................................................................................................................... 74
Appendix 9 .......................................................................................................................... 75
Appendix 10 ........................................................................................................................ 76
Appendix 11 ........................................................................................................................ 77

X
LIST OF FIGURES
Fig 1.1.1: Logo of SNPL .............................................................................................. 2
Fig 1.4.1: Flow diagram of PMD Process ................................................................... 8
Fig 1.4.2: Flow diagram of SMD Process ................................................................... 9
Fig 1.4.3: flowing diagram of slitting process .......................................................... 12
Fig 1.4.4: Flow diagram of filter making .................................................................. 12
Fig 2.1.1 Lamina processing flow Diagram .............................................................. 17
Fig 2.1.2: Stem processing flow diagram ................................................................. 20
Fig 3.1.1: Fishbone diagram of factor causing M.C variation after ex-CRS Cutter .. 24
Fig 3.1.2: S.D chart of moisture variation after Ex-cutter (Appendix 1) .................. 25
Fig 3.1.3: Mean Moisture after Ex-cutter (appendix 1)........................................... 25
Fig 3.1.4: Coefficient of Variation of weighcon Weight (Appendix 1) .................... 26
Fig 3.1.5: CPI of cutter before and after (appendix-4) ............................................ 35
Fig 3.1.6 Wax Thickness Before and after (appendix-4).......................................... 35
Fig 3.1.7: Percent expansion from Ex-cutter to Ex- Dryer (appendix-2 and 3) ....... 36
Fig 3.1.8: FV of CRS after cutter before and after (appendix-2) ............................. 36
Fig 3.1.9: FV of cut tobacco before and after implementation (appendix-5) ......... 37
Fig 3.1.10: FV distribution after and before after implementation (appendix-5) ... 37
Fig 3.1.11: Cp and Cpk of old and new boiler. (Appendix-6) ................................... 42
Fig 3.1.12: SD of stem pressure at HT of boilers (Appendix-6) ............................... 42
Fig 3.2.1: bin to cutter layout of CRS line ................................................................ 45
Fig 3.2.2: Angle of bulk Belt (left) smoothing of Belt (right) ................................... 47
Fig 3.2.3: Feeder and CRS bin layout of four bin ..................................................... 48
Fig 3.2.4: design of cover for spillage ...................................................................... 48
Fig 3.2.5: Spillage before and after instillation of cover ......................................... 49
Fig 3.2.6: Pan design (left), stand (right) ................................................................. 50
Fig 3.3.1: Admoist inter-operational time (Appendix-10) ....................................... 52
Fig 3.3.2: CRS dryer inter-operational time (Appendix-10) ..................................... 52

XI
LIST OF TABLES
Table 3.1.1: Temperature after Ex-admoist before ................................................ 27
Table 3.1.2: Temperature after Ex-admoist after ................................................... 27
Table 3.1.3: Filling value jump (appendix 2and 3) .................................................. 35

XII
ABBREVIATION
SNPL: Surya Nepal Private Limited
PMD: Primary Manufacturing Department
SMD: Secondary Manufacturing Department
EHS: Environment Health and Safety
QUAS: Quality Assurance
CRS: Cut Roll Stem
FV: Filling Value
HT: Heating Tunnel
CTS: Cut Tobacco Storage
MC: Moisture Content
DRF: Dust removal Filter
VOV: Vibrating over vibrating
SD: Standard Deviation
Cp: Process capability
Cpk: Process Capability Index
mm3/gm Cubic millimeter per gram
cc/gm cubic centimeter per gram
kg/hr kilogram per hour

1
CHAPTER 1. INTRODUCTION
1.1 Company profile Introduction
Surya Nepal Private Limited (SNPL) is an Indo-Nepal-UK joint venture, which started operations in Nepal in 1986. Surya Nepal Private Limited is one of the largest private sector enterprises in Nepal and a subsidiary of Indian Tobacco Company (ITC) Limited, India. The balance shares are held by 17 Nepalese individuals & Corporate shareholders and British American Tobacco (Investment) Limited, UK.
SNPL’s commitment to its corporate vision “enduring value for all stakeholders” has been uncompromising through the years and is reflected in every product, process and service provided by the company.
The company has been recipient of prestigious FNCCI National Excellence Award for being the best managed corporation in Nepal and honored as most systematic company. The company is also the recipient of various national safety and environmental awards like British safety council award, National Safety Award and is certified with Quality Management System Standard ISO( International Standard organization) 9001:2001, Environmental Management System Standard ISO 14001:2004, Occupational Health and Safety Management System Standard ISO 18001:1999, Social Accountability ISO 8000:20001. Portfolio of Business
SNPL’s business includes manufacture of Cigarettes, Safety Matches and Agarbatti in Nepal with a total turnover of over US $175 million .
SNPL has more than 90% of Nepal’s cigarette market and is the single largest contributor to the national exchequer of 3.5% of country’s revenue. And top manufacturing company in tax paying. Total Number of Permanent employees working in Tobacco division of Simara factory of SNPL consists of 47 managerial and 353 non-managerial staff. It also employee many workers on contract basis.

2
SNPL Logo
SNPL logo stands for company ethos and the beliefs it hold true as a company. It reflects company’s passion for quality and excellence and compelling vision to create enduring value for all its stakeholders.
The mountain stands for SNPL deep roots in Nepal, and connotes a sense of solidity and permanence, symbolic of its position as the nation's foremost professionally managed company. The rising sun stands for leadership as well as company passion for excellence. It encapsulates the pioneering spirit that inspires company to create and innovate products that adhere to the highest international standards as well as create enduring value for its stakeholders. The sun also represents the optimism that it feels for the future, and its deep conviction that, by generating employment, earning foreign exchange and through various CSR efforts, help create a better, brighter tomorrow for everyone.
Fig 1.1.1: Logo of SNPL

3
1.2 Vision and Values
To be an internationally benchmarked multi-business corporation in Nepal, delighting domestic consumers with a proud “Made in Nepal”. To be a partner in nation-building and creating enduring values for all stakeholders.
Core Values
a. Nation Orientation
Company is aware of its responsibility to generate economic value for the nation. In pursuit of its goals, company will make no compromise in complying with applicable laws and regulations at all levels.
b. Trusteeship
 As professional managers, employees are conscious that SNPL has been given to us in “trust” by all its stakeholders. It will actualize stakeholder value and interest on a long-term sustainable basis.
 Highest standard of Corporate Governance – Absolute Integrity.
c. Excellence
SNPL do what is right, do it well and win. It will go the extra mile and seek superiority in all that we undertake.
d. Customer Focus
SNPL is always customer-focused and will always strive to surpass customer expectations in terms of value, product quality and satisfaction.
e. Respect for People
 We are result-focused, setting high performance standards for themselves as individuals and teams.
 SNPL will always respect and value people and uphold human dignity.
 SNPL acknowledge that every individual brings a different perspective and capability to the team and that a strong team is driven by the variety of perspectives within it.

4
f. Innovation
SNPL will constantly pursue newer and better processes, products, services and management practices.
g. Corporate Governance
Corporate Governance is a systemic process by which companies are directed and controlled to enhance their wealth-generating capacities. The governance process should ensure that companies are managed within the applicable statutory parameters in a manner that meets stakeholders’ aspirations and societal expectations. The operations of Surya Nepal Private Limited are governed by its Corporate Governance Policy. SNPL believes that any meaningful policy on corporate governance must provide empowerment to the executive management of the company, and simultaneously create a mechanism of checks and balances which ensures that the decision-making powers vested in the executive management are not only not misused, but are used with care and responsibility.

5
1.3 Policies and Philosophy Environmental Policies
The company is committed to preserve environment by taking the following proactive measures in its activities.
 Company with all applicable national environmental legislations, regulations and EHS guidelines and will endeavor to go beyond compliance over a period of time.
 Practice pollution prevention techniques in its operations
 Conserve natural resources like Energy, water by optimizing the usage.
 Continuously strive to reduce waste generation and lay emphasis on reuse and recycle of wastes.
 Monitor and reduce dust level and emission in ambient air, hence strive to offer clean and green environment to its employees, communities and contractors.
 Achieve continual improvement through regular review of Environmental Management Systems.
 Promote environmental awareness amongst employees, suppliers, and contractors through training and communication.
 Set an example of leadership of leadership in the field of Environment Management System through adoption of Globally Acknowledged Environment Management System.
1.2.2 Energy Policy
Surya Nepal is committed to continuously improve our energy performance in all our activities, products and services so as to make it environmentally sustainable for future generations.
To meet the above, they will strive for:
 Energy efficient goal power distribution, fuel consumption and steam generation.

6
 Nurturing energy efficient designs and technologies for all future acquisitions, wherever practicable.
 Enhancing utilization of energy resource, updating hardware, operational practices and employs cleaner and efficient technology as appropriate.
 Recognizing efforts of our employees and their family members in energy conservation initiatives.
 Yardsticks, which drives us to monitor and improve energy performance through periodic reviews and skill up gradation of our employees.
 Trains employees to make SNPL, the pace setter in the area of energy conservation.
 Benchmark continuously our performance against the best in the world.
1.2.3 EHS Policies
 To contribute to sustainable development through the establishment and implementation of environment standard that is scientifically tested and meets the requirement of relevant laws, regulations and code of practice.
 To take account of environment, occupational health and safety in planning and decision-making.
 To provide appropriate training and disseminate information to enable all employees to accept individual responsibility for environment, health and safety, implement best practice and work in partnership to create a cultural of continuous improvement.
 To install a sense of duty in every employee toward personal safety as well as that of other who may be affected by the employees’ action.
 To provide and maintain facilities, equipment, operation and working conditions which are safe for employees, visitors and contractors at the company’s premises.
 To ensure safe handling, storage, use and disposal of all substances and materials that is classified as hazardous to health and environment.
 To reduce waste, conserve energy and promote recycling of materials wherever possible.

7
 To institute and implement a system of regular EHS audit in order to assure compliance with laid down policy, benchmarked standards and requirement of laws, regulations and applicable codes of practice.
 To proactively share information with business partner towards inculcating world-class EHS standard across the valve chain of which SNPL is a part.
1.2.4 Quality Policy
We are committed to satisfy our customer quality product, processed and manufactured by harnessing the potential of all people in a safe and hygienic environment at competitive cost, and delivered on schedule. It will be our continuous endeavor to strive for bringing in continual improvement in our quality attributes for the benefit of customer
1.2.5 Social Accountability Policy
We are committed to implement social accountability standard in our operations through adoption of the following:
 Comply with national and other internationally acknowledged law/SA requirements with due respect to the principle of other instruments.
 Conduct operations with due regard for environments and provide a safe and hygienic work place for each employee.
 Continue sustainable development through improving social performance by enhancing the scope of corporate social responsibility.
 Respect employees and considers as valuable assets.
 Communicate the policies to all employees and interested parties.
 Continuously keep abreast and follow the least change that may benefits society at large for enduring sustenance.

8
1.4 Major Department in SNPL Primary Manufacturing Department
PMD process lamina and stem and make them suitable for making cigarette. PMD has two line of process each for lamina and stem. Both lamina and CRS goes through similar processing. They are conditioned (stem in ad-moist and lamina in DCCC) than bulked in bin for 2 hours minimum. Then they are cut and passed through H.T for expansion by steam. After that they are dried in dryer and CRS is stored in silo. Stem is mixed with lamina after dryer in a ratio of 20:80 and flavored. Final cut tobacco are stored in CTS bin. As per demand in SMD cut-tobacco are supplied by pneumatic conveyer at 14+0.5 moisture.
Fig 1.4.1: Flow diagram of PMD Process
Reweight
Cutting
Conditioning
Expansion in H.T
Mixing
Drying
Mixing &
Flavoring
Storage in CTS
Supplied to SMD

9
Secondary Manufacturing Department
Final cut tobacco stored in CTS bin, are supplied by feeding and then the pneumatic conveyer at 14+0.5 moisture to the SMD as per demand of making machines. The making machine produce the cigarette rod of required specification and the assembler unit of making machine assemble filter to the cigarette rod (besides the plain cigarette). The cigarette from the making machine is transported to packing machine via trolley and is fed to packing machine in order to produce the packets of required specification in packer unit. The wrapper unit of packing machine adhere excise stamp and wrap the Biaxially oriented poly propylene over the packets and seal them after proper folding. The over wrapper machine wrap Biaxially oriented poly propylene over the bundle of 10 or 20 packets as per the specification. The outers are then fed to boxing room to pack the outers in the corrugated fiber cartoon boxes as per the specification. The finished goods ready for shipment are then temporarily stored in shipping room.
Fig 1.4.2: Flow diagram of SMD Process
CTS bin
Pneumatic conveyor
Feeding conveyor
Making machine
Wrapping machine
Packing Machine
Overwrapping machine
Central conveyor
Boxing room
Shipping room

10
QUAS
QUAS daily checks different parameters of PMD and SMD. Like moisture content and filling value at different processing stage of tobacco along with quality ratio. Loose end, moisture at catcher and packer, packet sealing, weight etc. of final Cigarette. Following instrument are used for quality testing. 1. Loose end tester 2. TQM 5  Used to measure loose end of cigrattes. Cigarettes are rotated 270 times and gm of tobacco lost from cigarette is calcuted.  Used to measure pressure drop and circumference of Cigarettes. 3. STC jel- sieves 4. Humidity Cabinet  Use to calculate quality ratio of tobacco. HC maintain desired environment i.e. RH and temperature for require amount of time. 5. Lab Gauge 6. Desnimeter

11
 Displays instantaneous moisture, nicotine, sugar and temperature  Use to measure height of compressed tobacco. 7. Auto Hardness Tester 8. Moisture Oven  Use to test Firmness of cigarette. Fix weight is applied for certain period of time and deformation of cigarettes rod is measured.  Use to evaporate moisture of tobacco. Sample are kept at 1100C for 3 hours. 9. Water cooled Desiccator 10. Packet Seal tester  Use to absorb any moisture remaining after Moisture oven.  Use to test sealing of packet. Certain amount of air is supplied for 5 seconds, inside the packet and amount of leakage is measured.
Addition to this smoke panel test cigarette after each batch of production. IPQRS is carried out.

12
Slitting Complex
The rejected cigarette from SMD after sorting goes to slitting complex. After sitting only tobacco is added back in PMD after lamina dryer as smalls.
Filter manufacturing department
Filter rod used in filter cigarette are manufacture in this section. Filter rod are made from the fiber called acetate to. Two machines makes different size filter for king size 85mm and regular size 70mm cigarette
Fig 1.4.4: Flow diagram of filter making
Cigarette Feed
Sieving
Slitter
Sieve
Smalls
Sand
Paper/filters
Added back to PMD after Lamina Dryer
Fig 1.4.3: flowing diagram of slitting process
Raw material
Blooming
Application of plasticizer
Wrapping in PWT
Garnishing and Cutting
Collecting
After quality inspection displaced to SMD

13
1.5 Products of SNPL
Surya Nepal Pvt. Ltd, Simara, business is all about manufacturing and marketing of cigarettes.
Major cigarette brand of Surya Nepal are:
 Bijuli
 Chautari
 Pilot
 Khukuri
 Shikhar
 Surya
 Surya 24 Carat

14
CHAPTER 2. PROJECT AREA INTRODUCTION
2.1 PMD
PMD receives dries leaves (lamina) and stem from leaf Department at MC of 9-11. There is separate processing unit for stem and lamina one each. Final cut tobacco is stored in bin and delivered to SMD at 14.5+ 0.5 MC. Lamina processing is describe as below
a. Receiving of leaf
After leaf are issue for processing they are reweighted and send to bale turning device.
b. Bale Tipping Device (BTD)
Bale of 150 kg and 200kg of leaf are fed to the BTD through roller conveyer. Upper side of bale of bale is open manually and bale is fed to BTD. BTD rotates bale at 1800. And other side of bale is open manually. After that bale are passed to slicer through belt conveyer.
c. Slicer
The bale slicer divides dry compressed tobacco bales into the form suitable to conveyed and fed directly to DCCC. Slicer cut bales into 3pieces i.e. 2 cut for 150kg and 4 pieces i.e. 3 cut for 200kg.
d. DCCC ( Direct casing and conditioning cylinder)
Conditioning is achieved by 2 mechanism occurring simultaneously within the DCCC process. Conditioning by condensation and direct moisture addition from water sprays. Condensation process is controlled by regulating the dry bulb temperature of air flow. Air flow is co-current with product flow. An automatic temperature controller compares the temperature set point with actual value and output.
Water and Casing are sprayed in atomizes form to prevent spot formation. Atomization is done by steam.
e. Lamina Bin
Conditioned lamina are arranged in layer across the length of bin. At least two grade of each grade of tobacco is made in bin. Minimum of two hours of bulking is done.

15
Reason for bulking Homogenous mixture of grades in a blend. Uniform moisture content of blend before lamina cutting.
f. Airlift
Conditioned tobacco from bins is discharged into VOV (vibrating over vibrating) which transfers it to the air leg of the airlift.
Reasons for Airlifting to separate foreign material stone metal present in the leaf before feeding to cutter.
g. Sieve Complex
It is use to separate small lamina particles (through< ¼”). These small particles are separated to reduce dust formation in cutter as it is already small and need not to be cut. The particles coming through ¼ sieve is added back to lamina after cutter.
h. Lamina cutter
Cutter consists of two sections, a packer/feeder and a cutter. Transport chains convey tobacco to the mouth piece. The mouth piece is forced down to tobacco by constant force. This force is called cheese pressure. As the tobacco leaves the mouthpiece, it is cut by the rotating knife drum. A grinding device, which moves as long the axis to and fro parallel to the knife drum constantly sharpens the knifes. Cutting width can be adjusted by changing the speed of the transport chain.
Lamina is cut at 30 CPI and 18KN cheese pressure.
i. Weigh conveyer
Weighcon measures and set the flow rate of tobacco passing through it. It is essentially a band conveyer with load sensor. Before weighcon a Gravity feed pipe is provided. With a variable speed machine, the band speed is automatically regulated through control loop so that the actual flow rate along the band coincide with the present desired flow rate.
j. Lamina Drying
The purpose of lamina drying is to expanded the lamina and reduce incoming moisture to desired moisture level.

16
It consists of two unit.
i. Heating tunnel
HT is used to for expansion of tobacco particles by application of free steam. Steam at a pressure is released through small holes creating a high velocity. Cut tobacco is made to float on thus loosening the product. The final temperature of product leaving steam is about 95oc.
ii. Dryer
It is used to dry cut expanded lamina uniformly preserving gain in expansion.
Process
The high temperature and high moisture cut tobacco comes in contact with high volume and heated process air at a particular set temperature. Flash drying by evaporation takes place initially there by preserving the pre-expanded cut tobacco. Subsequently, the steam jacketed paddles and steam heated paddle blades transfer the heat to the cut tobacco thereby driving water particles lamina. The process air get gets more water for evaporation and evaporates, there by cooling the product. The shell rotates repeating the process to desired label.
Feedback The deviation of output mc from desired level is measured and cylinder wall temperature changed by changing steam pressure.
k. Mixing and flavoring
CRS from bin is added to lamina after dryer at the ratio of 20:80. Than product is fed to flavoring cylinder. Flavor are aromatic materials added to final tobacco. A weighcon before the flavoring cylinder gives the input tobacco flow and flavor is sprayed accordingly as per blend setting. Atomized flavor are sprayed while rotating the cylinder.
l. CT bins
Purpose of CT bins is to achieve a homogenous mix of lamina with CRS/ Add backs and keeps Inventory for SMD. Humidity is maintained at CT bin at 65+5 with Jet spray nozzle.

17
Lamina Line
Fig 2.1.1 Lamina processing flow Diagram
Leaf Receive
Reweight
Airlift
Sieving
Blending /Bulking
Bale Opening
Slicer
Conditioning & Casing
Sieving
Mixing & Flavoring
Cutting
Drying
Heating Tunnel
Storage (CTS)
Sieving Complex
Dust
Dust/Sand
Dust/Sand
Smalls
Cut Stem
PMD DRF
Through 5/16”

18
CRS Processing line is described as below
a. Stem feed:
Stem CFC is fed to the twin band conveyor where top side is opened and inspected. The open cfc then goes to stem tipper where it is lifted and tipped towards the hopper at an angle of 1600 .Hopper can hold up to 6-7 CFC of stem and it feeds to the discharge VOV, sieve VOV, fast moving band, airlift, GFP, metering band and finally to admoist.
b. Admoist:
In Admoist moisture is addition and absorption. This process is facilitated by Condensation, Water addition, tumbling effect.
Conditioning process:
GFP and weighcon is used to give uniform supply to admoist. The stem entering through the feed end is hit by steam sprays from the central large pipe. The steam spray adds moisture by condensation and also increases product temperature. The atomized water sprayed from the top enables water particle deposition on the tumbling stems. Since the stems are being continuously tumbled in steam and water, absorption takes place mainly due to capillary action from the ends.
c. Stem bins:
After conditioning the stem is stored in stem bins to bulk condition stems i.e. uniform moisture across the layer.
d. Stem cutting:
Cutting principle is similar to lamina cutting where inlet MC is 38±2% and cutting speed is increased to 160 CPI for stem.
e. Heating tunnel
The cut stem now move towards the HT where it comes contact with high pressure steam for expansion which is important to increase the FV.
f. CRS drier
The purpose of drier is to dry cut and expanded tobacco to required moisture preserving FV again. CRS dryer is similar to Lamina Dryer.

19
g. Classifier
Tower classifier is used to separate improperly cut stem (heavies) from good CRS. After drying, the CRS is fed to classifier through a VOV. A VOV delivers an evenly distributed carpet of CRS from the dryer to the winnower. The action of winnower is to gently throw the incoming CRS to thin air which is moving upwards to the top in direction of suction. The heavy particles that falls down are called heavies and these heavier particles are further separated in a mesh where smaller heavies are rejected and held over mesh is reprocessed. The CRS is transferred from classifier to CRS bin through air lock/VOV.
h. CRS bin
The purpose to store expanded cut stem after drying and classification ready for add back to main blend.
i. Mixing and Flavoring
CRS from bin are added to lamina after dryer and flavored along with lamina and stored in CTS bin.

20
Stem Line
Fig 2.1.2: Stem processing flow diagram
Bale Opening
Airlift
Sieving
Bulking (Silo)
Conditioning
Cutting
Heating Tunnel
Drying
Sieving
Classifier
Storage (CRS bin)
Dust
Dust/sand
Winnowing
Heavies
PMD DRF
Mixing & Flavoring
Storage (CTS bin)
Cut Lamina

21
CHAPTER 3. PROJECTS
Following are the projects I carried out during my internship period.
1. Research and data Analysis
a) Admoist protocol Test
b) Increase the filling value of surya
c) Cp & Cpk of CRS dryer
2. Problem solving
a) Maintain the feed gap in CRS cutter
b) Decrease the Spillage at product bin area
c) Design of Pan for Sampling at HT and stand for Serrico Trap
3. Optimization
a) Optimization blend change time
3.1 Research and Data Analysis Admoist Protocol Test
a. Scope
Admoist at SNPL is newly purchased. For any newly purchased machine protocol has to be tested, in order to verify that machine has been installed correctly and machine is operating at proper setting as per manufacture clam. Protocol of admoist was Tested before but few point of protocol failed i.e. S.D of M.C<0.5, Mean Moisture is within range of 38±2. I was assigned to find out the causes of protocol fail and take more data after adjustment had been made.
 Filling value is always measured in mm3/gm.
 Moisture content in % throughout the report

22
b. Introduction
Before stem are cut its moisture content have to be increase from 11±2 to 38±2 as stem at low moisture are brittle, the process of increase moisture is done by conditioning. Conditioning is the process of spraying steam or water in dry stem or lamina to expand them to their original form. Conditioning can be done by two method hot and cold. In hot condition steam is sprayed over stem in closed chamber at fixed temperature and pressure and for certain time (as per the standard protocol of company). And in cold conditioning water is used instead of steam. This help stem to gain moisture which they lost during drying. Conditioning helps in smooth cutting and better expansion of CRS on heating tunnel. For cold conditioning stem has to be bulked for 12 hours and for hot conditioning 2 hours. Bulking is the process of keeping stem/lamina in a container so that moisture content is uniformly distributed among them. The machine used for stem conditioning in SNPL is known as admoist.
Admoist raise both moisture and temperature of product, whilst achieving complete penetration of conditioning throughout the cross section of individual particles. Admoist can be used for addition of casing or other additives which is combined with the conditioning process or for heating stems prior to rolling.
c. Principle
Product is conveyed through the Admoist by the action of multi-bladed rotor, supported within a U shaped trough. The center of the rotor is a perforated tube, supplied with low pressure steam via a rotary union. At intervals along the length, atomized water sprays are directed at the product above. Through penetration of moisture is achieved by the combination effect of steam percolating from the rotor spray pipe, together with the finely atomized sprays from above. Through mixing is achieved by means of gentle tumbling action, which ensures that faces of all particles are continually being presented to the steam and water sprays.

23
d. Specification
Flow rate (inlet): 1500kg/hr.
Flow rate (outlet): 2175kg/hr.
M.C. (in): 10-12.5% (out): 38%
Paddle diameter: 0.9 m
Trough Length: 4.5 m
Angle of inclination: 50
Paddle Rotation: 5.13 rpm
Rotation: Clockwise in direction of product flow
e. Objective
 To collect data to Test required protocol
 To analysis the previous data and find out the possible cause of protocol failure.
 To finding the solution for causes.
f. Methodology
Data of 30 Operation was analyzed. 10 Samples of each operation was taken after CRS- cutter and its moisture content was tested. Additional 10 operation was tracked after making necessary adjustment. Addition to this CV of mass flow was analyzed using data log of weighcon.
Data collected were analyzed using scatter diagram. In order to pass the protocol out of 30 operation, S.D of at least 29 operation should be within specification limit of < 0.5, moisture mean should be within 38±2 and S.D of input weight variation < 0.5%.
g. Finding
From observation and analysis of data collection following fish-bone diagram was constructed to find the possible cause moisture variation.
Most important factor in determining MC after Ex-cutter was found to be amount of steam consumed and uniform flow of raw material.

24
Moisture Content variation in cutter above 0.5
Raw material
Machine
Method
Mother Nature
Man
Length
Size distribution
Intrinsic Property
Moisture Content
Type (cold or hot)
Bulking time
Temperature
Power failure
Humidity
Sampling Method
Measuring Instrument Least count
Amount of Material Supplied
Calibration
Uniformity of filling
Uniformity of water, raw material and steam flow
Fig 3.1.1: Fishbone diagram of factor causing M.C variation after ex-CRS Cutter

25
h. Result
Fig 3.1.2: S.D chart of moisture variation after Ex-cutter (Appendix 1)
Fig 3.1.3: Mean Moisture after Ex-cutter (appendix 1)
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0
5
10
15
20
25
30
35
S.D
Operation
S.D Chart of Moisture
35.50
36.00
36.50
37.00
37.50
38.00
38.50
39.00
39.50
40.00
0
5
10
15
20
25
30
35
M.C %
Operations
Moisture Mean

26
Fig 3.1.4: Coefficient of Variation of weighcon Weight (Appendix 1)
i. Discussion
Only one operation SD of moisture content was found to greater than 0.5, all mean value was found to lie between 38±2. The process Cp was found out to be 2.2 and Cpk 0.98. Which proves that system is capable. Low value of Cpk is was observed due to shifting of mean value toward lower limit. The main reason for that was observed to be “MC after Ex-cutter is very high, so it losses it moisture rapidly. Due to this if sample where kept for longer time in QUAS before taking weigh in tin than there moisture is found out to be low”.
In some cases flow of HVM Stem were found to be non-uniform. Cause of this non- uniformity was larger and variable thickness of stem in this grade. Longer steam occupies larger volume but has less mass so even when weighcon speed is 100 % and there is product in GFP, criteria for mass is not met.
No future action were required as S.D < 0.5 and mean value between 38±2.
0.00%
1.00%
2.00%
3.00%
4.00%
5.00%
6.00%
0
5
10
15
20
25
30
35
Coefficientof variation of weighcon Weight

27
j. Further observation made during internship
Due to low FV of CRS from regular interval in QUAS daily report after 17 aswin. Temperature of product at 1 meter distance from outlet of admoist was checked. It was found that temperature was higher than desired temperature.
S.N
Temperature 1(0C)
Temperature 2 (0C)
Temperature 3(0C)
1
76
77
78
2
78
78
77
3
77
76
77
Table 3.1.1: Temperature after Ex-admoist before
I Cause
Failure of Pressure reducing valve to maintain set pressure of 0.3-0.4 bar. Line pressure was changing as per main line pressure variation.
II Solution
Main line pressure was decrease to 5bar from maximum pressure by boiler i.e. 7-8 bar.
III Result
Temperature 3 samples of 3 operation was tracked result are as flow
S.N
Temperature 1 (0C)
Temperature 2 (0C)
Temperature 3(0C)
1
71
69
70
2
69
71
71
3
70
71
70
Table 3.1.2: Temperature after Ex-admoist after
k. Recommendation
The temperature after ad-moist should be check in regular interval of time i.e. 1week. Moisture deviation after cutter should be checked daily. (MC and its SD is checked by QUAS daily and recently after implementation of PPQRS temperature is also checked daily)

28
Increase the filling value of Surya Tobacco
a. Scope
This project mainly focus on way to improve the filling value of Surya blend. Filling value of tobacco depends on various individual process used in processing, aside from its own intrinsic property. Various process like cutting, expansion, storage effect the filling value of blend. I was assigned to this project to find out effect each process have on FV so that further action can be taken for improvement of process.
b. Introduction
Filling power is define as the ability of a unit weight of the material to occupy space. Filling power is intrinsic property of material. It is measured in mm3/gm or cc/gm. Firmness is define as a cigarette rods resistance to compression. Each Manufacture established an internal standard of firmness of his cigarette brand. One of studies conducted by (Wong and Wilson, 1976) concluded that the relationship between cigarette firmness, in term of weight savings, and tobacco filling power was highly significant (r=0.83). Other researcher also support this facts. To illustrate: The effect of Filling value and cost , Assuming a finished blend cost of Rs.600 per kg, a 4 percent increase in bland filling power will save manufacturer approximately RS 1.02 crore per billion of cigarettes sold. Considering average weight of cigarette of 850mgms per cigarette. (Semfield, 1973)
Filling power of tobacco has great economic important in tobacco industries as well as affects every parameter of final cigarettes produce like losses end, firmness, density, burning rate etc. Filling power of tobacco varies with varieties of tobacco leaf and even within different part of same leaf. Steps in primary manufacturing of cigarettes and effect on tobacco filling power of both stem and lamina (filling power are measured after sample are kept in humidity cabinet and maintained around 14 percent)

29
a. Conditioning Increase in filling value due to expansion
b. Cutting Increase FV due increase in gap between two tobacco pieces
c. Heating Tunnel Increase in FV due expansion by steam
d. Drying Decrease in FV due to contraction of cell and breakage
e. Mixing Change in filling value as per percent of mixture
The loss or gain of moisture or other volatiles, the physical state of the tobacco, and the addition of casing materials and humectants all affect tobacco filling power during handling. Changes in filling power due to moisture gain or loss are reversible whereas the other changes are not. Thus, a cigarette left in a high humidity room will soften considerably due to absorption of moisture but will regain its firmness if moved to a lower humidity area. As tobacco loses moisture, it also becomes more fragile; i.e., it tends to break more easily. This property is known as fragility. Unfortunately, fragility is generally directly related to filling power; i.e., the higher the filling power the greater the fragility. Because of the sensitivity of filling power to changes in moisture content, its measurement must be performed under carefully controlled conditions of relative humidity and temperature. Even under the most carefully controlled humidity conditions, however, moisture correction factors may have to be applied to correct for small and inadvertent changes in relative humidity.

30
c. Methodology
For the baseline data, five operation were tracked. Sample of CRS from Ex-cutter, Ex- H.T, Ex-bin and Lamina. Ex-Cutter, Ex-H.T, Ex-Dryer sample were kept in humidity Cabinet for 2day and 1day respectively and their filling value was calculated using densimeter and MC. Densimeter consist of graduated cylinder of radius(R) with a closely fitting plunger and weight. The procedure for measuring height is a known weight i.e. 20 ±0.05 gm. weight is place in cylinder and plunger is inserted into cylinder gradually weight of 3 kg is applied. After 30 sec height (H) of plunger is measure from based of cylinder . Volume occupied by sample= πR2H. Filling value = volume* moisture correction factor.
These data were analyzed to find the pattern, in order to find the main cause of low filling value. Different research paper from BAT, American Tobacco, Phillip Morris, imperial Tobacco etc. Were studied to find way to increase filling value. After making necessary change again data of addition 10 operation were tracked.
Total of 15 operation were tracked and about 500 samples were taken. Additional data were taken from daily report of QUAS.
Scatter plot and bar graph where used to compare between two data.

31
d. Finding( Research )
 Virginia tobacco have high sugar content. Higher sugar content increase the equilibrium moisture content. Hence they have lower filling value. (Taylor, 1976)
 Filling value is very sensitive to moisture change. Some research argue that 1% change in moisture will cause 10% change in FV.(Akehurts, 1968) other have conclude that that 1% change in moisture will cause 4% change in FV. (Semfield, 1973) correction factor used at Surya Nepal show that 1% change in moisture causes 6.5-7.5% change in FV.
 Filling power is the function of fragility. So more filling value does not always mean more economic importance. More suitable factor is filling power index. For example, assume that the fragility of tobacco "A" is 0.06 and that its filling power is 4.0c.c. /gm. Assume that tobacco "B" has a fragility of 0.01 and a filling power of 3.9 c.c. /gm. In this case a fragility of 006 would mean a 6 percent 10ss during handling and processing and 0.01 would mean a 1 percent loss. The "economic filling power index" of "A" would be 4.01 1.06 or 3.78 c.c. /gm. The economic filling power index of "B" would be 3.9/1.01 or 3.86 c.c. /gm. Thus "A" would be less desirable although its filling power is greater - assuming, of course, that the price for both is the same. (Semfield, TJI, 354, 4/80)
 Type of dryer has vast impact in filling value. Counter flow dryer are better than co-flow. Their in fv is bewteen 0 to 3.6%. Hot air with cool tobacco is bad as they may cause tobacco to dry at inlet zone and cause tobacco praticle to attach with each other. (Gibb, 1962), (Pedersen , 1990).
 Regarding fiber length different researcher have different point of view (Wochnowski, 1989) said fiber length effect up to 11% in filling value.
 Some researchers concluded that 32 is best CPI for lamina. (Semfield, TJI, 509, 6/80). Other concluded that 24 cut are best. Lower cut is supported by the fact that as width increase apparent density decrease and practically fragility decrease increasing filling value. Lanore(1945) has emphasized this influence,

32
estimating that an increase in the width of the cut equal to 0.1 mm would allow the optimum weight to be lowered by 1.6%. More recently, Kamachi, & co. (1965), Flesselles(1966), have confirmed this observation but evaluate this effect at a level between 1.3 and 3%. Sharpness of blade play important role in filling value. Since the apparent density decreases by about 8% when the cutting angle decreases by 10 degrees. For a given cutter, it is therefore of importance to watch the quality of the sharpness, and thus to maintain a sufficient rate of advance in the mill. A well sharpened blade makes possible a cleaner cut and hence a better particle size distribution. And higher temperature cause deformation on strands. So low cutting temperature is preferred. (Pietrucci, 1974)
 FV of tobacco on average reduce by 1% for each 1 oC increase in temperature. Best CRS HT steam pressure is 5bar. (Wochnowski, 1988).
 Longer stem expand more than shorter stem due to pressure drop. Reconstituted tobacco can be made from dust, residues, stem and added back to lamina. As reconstituted tobacco have higher filling value than dust. (De Grandpre, 1887)
 Temperature 85 0F at 21.5 % MC of tobacco is best environment for cutting (Drake, 1975), if temperature is increase 90-95 there is 0.6-1.2g/cc loss in filling value. Or else MC of 22-22.5% at 110 0F to 115 0F is best for cutting. (Philip Morris, 1984)
 Factors effecting filling values
 Type of Leaf
 Admoist temperature
 Bulking time
 Conditioning type
 Temperature of cutting
 Cheese pressure of cutting
 CPI of cutting
 Angle of cutting
 Sharpness of cutting
 Moisture at cutting
 Steam pressure at H.T
 Steam ratio at H.T
 Moisture before drying
 Type of dryer
 Flavoring and casing
 Moisture at measurement
 Temperature at measurement

34
e. Finding ( Data collection and analysis )
 F.V after Ex-cutter was below average below only 4.2 cc/gm.
 Expansion from cutter to H.T of both lamina and CRS was with in speciation limit
 CPI of Cutter was below average i.e. 139 and non-uniform
 Steam pressure of CRS H.T could be increase
 Cheese pressure was set it 18 KN, Cheese pressure could be decrease for Surya
f. Implementation
 Calibration of Cutter was carried out. CPI of cutter increase from 130 to 166 and cutting was more uniform.
 Steam pressure of CRS H.T was increased from 4 to 5 bar.
 Cheese pressure of lamina cutter was reduce for NG to 15KN.
 As far as possible NG was cold conditioned.
 Temperature of damper of Lamina dryer was decrease.

35
g. Result
Filling value jump between process were as show below
Table 3.1.3: Filling value jump (appendix 2and 3)
CPI of cutter before and after maintinance
Fig 3.1.5: CPI of cutter before and after (appendix-4)
Product
Process from to
Jump Percentage
CRS
Cutter to H.T
22.28%
cutter to Bin
13.46%
Lamina
Cutter to H.T
15.10%
cutter to Dryer
8.10%
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0
10
20
30
40
50
Wax Thickness(Before) (mm)
139
166
0
20
40
60
80
100
120
140
160
180
Before
After
Cut per inch
0
0.05
0.1
0.15
0.2
0.25
0
10
20
30
40
50
Wax thickness(After)(mm)
Fig 3.1.6 Wax Thickness Before and after (appendix-4)

36
Expansion Percentage from Cutter to Dryer
Fig 3.1.7: Percent expansion from Ex-cutter to Ex- Dryer (appendix-2 and 3)
FV before and after calibration of cutter
Fig 3.1.8: FV of CRS after cutter before and after (appendix-2)
13.62%
8.11%
0.00%
2.00%
4.00%
6.00%
8.00%
10.00%
12.00%
14.00%
16.00%
Ex-cutter to Ex-bin
Ex-cutter to Ex-Dryer
CRS
Lamina
Percentage Jump
42.03
44.07
41.00
41.50
42.00
42.50
43.00
43.50
44.00
44.50
Before
After
Filling Value (mm3/gm)
F.V after Ex-cutter

37
Filling Value of final Cut- Tobacco (average of 40 Days before and after Implementation of findings from QUAS Daily Report)
Fig 3.1.9: FV of cut tobacco before and after implementation (appendix-5)
Fig 3.1.10: FV distribution after and before after implementation (appendix-5)
47.78
49.15
47.00
47.50
48.00
48.50
49.00
49.50
Before
After
Filling Value mm3/gm
Filling Value Cut Tobacco
0
1
2
3
4
5
6
7
8
9
10
11
46
47
48
49
50
frequency
Filling Value
Before
0
1
2
3
4
5
6
7
8
9
10
47
48
49
50
51
frequency
Filling Value
After

38
h. Discussion
Clean cut and uniformity of cut is very important for filling value. After calibrating cutter cuts were more uniform and CPI was near the SOP. Due to which filling value increased by 4%.
Increase in stem pressure cause increase better expansion of CRS due to higher ratio of stem and vapor.
Cheese pressure at cutter compress the tobacco for cutting. But this compression can result in decrease in FV as more high pressure may cause leaf to lose their elasticity. Due to this lamina will not expand properly at HT. Chesses pressure is set high for domestic blend which have high filling value, but for surya even 15KN cheese pressure is enough. At ITC 14 KN is used.
Higher temperature at dryer can cause case hardening of CRS which are added back after lamina dryer due to thermal sock. Temperature of Lamina Dryer outlet was decrease with from 650C to 610C.

39
i. Recommendation
 As sharpness of bland and angle of cutting has drastic effect on filling. Cutter cutting should be checked daily.
 Cheese pressure should be reduce to 15 KN for NG during each operation.
 Steam pressure should be check for uniformity random during operation.
j. Further scopes
 Optimization of steam to tobacco ratio.
 Experiment with CPI of both lamina and cutter.
 Experiment with flow rate, amount and temperature of air at dryer

40
Cp & Cpk of CRS dryer
a. Scope
In order to find out if system is capable of producing product in give specification limit, it capability should be checked. This is done by calculating process capability (Cp) and process capability index (Cpk). I was assigned to calculate Cp and Cpk of CRS dryer.
b. Introduction
The ability of a production process to meet or exceed preset specifications is known as process capability. Specification often called tolerances, are preset ranges of acceptable quality characteristics, such as output moisture for dryer. For a product to be considered acceptable, its characteristics must fall within this preset range. Otherwise, the product is not acceptable. Product specifications, or tolerance limits, are usually established by design engineers or product design specialists. In cause of drier it is output moisture should be within the tolerance limit of set value + 1.
Cp is valuable in measuring process capability. However, it has one shortcoming: it assumes that process variability is centered on the specification range. Unfortunately, this is not always the case. So Cpk is used to measure when mean has deviated from central position.
c. Objective
 Collected data of all input parameter at CRS dryer.
 Calculate Cp and Cpk of CRS dryer.
 Find the cause of lower value of Cp and Cp. if value are low.

41
d. Methodology
Moisture of input and output tobacco were taken in interval of each 100kg passes through weighcon after tail in. Total 10 data of each operation was tracked. Standard deviation of these data were calculated and follow formula where use to calculated Cp and Cpk. 퐶푝=( 푈푆퐿−퐿푆퐿 6휎 ) 퐶푝푘=min⁡( 휇−퐿푆퐿 3휎 − 푈푆퐿−휇 3휎 )
Where
휇 = the mean of the process
휎 = the standard deviation of the process
USL= upper specification limit
LSL= lower specification limit
Cp = 1: A value of Cp equal to 1 means that the process variability just meets specifications. We would then say that the process is minimally capable.
Cp < 1: A value of Cp below 1 means that the process variability is outside the range of specification. This means that the process is not capable of producing within specification and the process must be improved.
Cp >1: A value of Cp above 1 means that the process variability is tighter than specifications and the process exceeds minimal capability.
Cpk = 1: A value of Cpk equal to 1 means that the process is just capable meets specifications.
Cpk < 1: A value of Cpk below 1 means that the process is not capable to meet specifications.
Cpk >1: A value of Cpk above 1 means that the process is more than capable to meet specifications.

42
e. Result and discussion
It was found that Cpk value was greater than 1 when new boiler was in operation. But during old boiler operation steam pressure to dryer and HT was largely variable so SD of output moisture was also high due to which Cpk value was below 1.
Fig 3.1.11: Cp and Cpk of old and new boiler. (Appendix-6)
Fig 3.1.12: SD of stem pressure at HT of boilers (Appendix-6)
0
0.5
1
1.5
2
2.5
3
3.5
1
2
3
4
5
6
7
8
9
10
Old Boiler | | New boiler
Cp and Cpk of CRS dryer
Cpk
Cp
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0
1
2
3
4
5
6
7
8
9
10
Old Boiler | | New Boiler
SD chart of Steam pressure at HT

43
After interviewing with boiler operator it was found that old boiler was used only few days in month so no action were taken.
It was concluded that CRS Dryer was capable of producing in given specification limit. No action were required.

44
3.2 Problem solving Maintenance of Feed gap at CRS cutter CFP
a. Scope
In order to maintain constant flow of product at CRS cutter, product level at GFP should always be visible. But some of time, product at GFP of CRS cutter is empty. This causes non-uniform flow of stem to cutter which may result in uneven cutting and increase winnowing stems. I was assigned to this project to find causes and solution.
b. Introduction
GFP maintains the level of product within reasonable limit for continuity flow of product. GFP consists of 3 senor photo sensor.
First sensor: if product falls this limit belt below it stop it so product level can be increased.
Second sensor: after second sensor detect the product, than belt conveyer below GFP starts. And if product level fall below this sensor conveyer above GFP starts.
Third sensor: when product reaches this sensor it sends a signal to stop product flow to GFP.
Only second and third sensor are present in GFP at CRS cutter. Speed of belt conveyer can be control using Variable frequency drive.
c. Finding
 There is start time difference between VOV (2) and bin belt Conveyer (1) i.e. of 5 Sec. This cause big gap up to 3meter between stems at VOV as demand can vary from 1sec to 4sec too. During this time VOV (2) is started and product will move forward but stem from bin conveyer will not fall causing gap.
 There is start time difference between VOV (4) and belt conveyer (3) i.e. 1 sec this also helps to increasing gap between stem at feeder.
 Speed of belt conveyer(6) below feeder is high, so even if steam are filled above second sensor and there is demand GFP is emptied in 1sec before even stem from VOV(4) can supplied to GFP.

45
Fig 3.2.1: bin to cutter layout of CRS line
d. Implementation
 Start time between bin belt conveyer and VOV was decreased to 1sec by replacing delay switch.
 Belt conveyer (6) speed was changed between 8 between 20 to find optimized speed for all grade of stem. By hit and trial, it was found that best speed for VSN5/VSN5MY was 12.5±0.5, and for HVM was 15±0.5. Higher speed for HVM was due to larger size HVM stem which occupy less height when compressed.
e. Result
 There is no any gaps between stem in conveyers during whole operation.
 Product at feeder is visible 98% of total time of operation. It couldn’t be made to 100% as motor starts at 40 and take a 1.5 seconds to sync to set speed. So if product level is just above second senor when motor starts feeder is emptied due to high speed of belt conveyer.

46
Proposed solution
Increase tube size to 1.5m.
Increase diameter of tube.
f. Further action required
Speed of belt conveyer should be changed after change in grade of stem supplied.

47
Wastage reduction at product bin
a. Scope
Due to misalignment between belts, installation faults or dislocation of parts there is lot of spillage of cut tobacco at product bin. Spillage causes increase need of man- power, increase foreign particle mix with cut tobacco as spillage tobacco is mixed back by sweeping the floor, blockage of conveyer, increase dust level at CTS area.
b. Introduction
Conveyer are used to transport cut tobacco from bin to feeder of respective blend. Each bin has vibrating conveyer and at least one belt conveyer to supplied CT to feeder. CT at feeder of bin 3 and 4 are supplied by three belt conveyer, after vibrating conveyer. But all tobacco from belt conveyers are not transferred from conveyer a to b. Tobacco starts accumulating at belt of c and causes jam of whole system.
c. Finding
Problem 1
When tobacco is transported by belt conveyer a to b due to misalignment of belt and roller. Some tobacco is not transferred from a to b but carried by belt, this carried CT is spilled at floor.
Problem 2
Belt conveyer c of is dislocated. The surface have bulk at angle of 100. And due to misalignment of belt from central position, left end of belts surface is smoothen due to friction between roller and belt. Because of these two reason tobacco slowly start accumulating at bottom left side of belt and cause jam of whole feeder system over period of time. Which causes lot of spillage. And also lower part of belt doesn’t have chute so tobacco are spilled.
Fig 3.2.2: Angle of bulk Belt (left) smoothing of Belt (right)

48
Fig 3.2.3: Feeder and CRS bin layout of four bin
d. Solution
Problem 1 a cover was design as below and attached at top of belt conveyer, so that spillage tobacco will fall in cover and then to belt conveyer (b). Detail design is at (appendix-7).
Fig 3.2.4: design of cover for spillage
Problem 2 Chute was installed at bottom of conveyer c and belt surface was made flat.

49
e. Result
Problem 1: Spillage was reduce to zero Kg per day.
Fig 3.2.5: Spillage before and after instillation of cover
Problem 2: Jam problem was reduce at conveyer from average of once per day to 1-2 times a week.

50
Design of pan for HT sampling and stand for Serrico trap
a. Scope
For PPQRS, sample from HT has to be taken. As temperature of product at HT is very high i.e. 900C even gloves is not enough to collect sample. So I was assigned to design a pan to facilities for sampling.
In order to hanging serrico trap at different point in factory, stand was required.
b. Solution
Pan and stand as following was designed. Detail of design is at appendix 8 and 9 respectively.
Fig 3.2.6: Pan design (left), stand (right)

51
3.3 Optimization Optimization of blend change time of CRS line
a. Scope
Operations have time gap between each other. This time gap has to optimize such that no mixing occur and minimum time is lost in idle of machines. Standard for this time gap is already assigned experimentally before. I was assigned to observe if ongoing time gap is optimized or not and make necessary changes in time gaps.
b. Introduction
When operation has to be changed like Surya blend has to operate after khukuri blend there has to be certain time gap between these operations so that these two blend doesn’t mix up. This time has to be short as far as possible.
When cutter finish cutting, it takes certain time for that CRS to reach HT and come out of dryer. So when cutter finishes cutting last blend at has to be stop for some time, this time is known as blend change time. When operation starts, it also takes some time to reach HT during this time pervious operations dryer should be emptied.
c. Methodology
8 operation were tracked from bale opening to CRS bin. Time for each stage of process where calculated. After making necessary adjustment additional 4 operation were tracked to verify the implementation.
d. Finding
Total time emptying CRS dryer was taking longer time than SOP. It was observed that tail out time was not enough, extra 4 minutes were required to empty dryer.
e. Action taken and Result
No action was required at admoist as average cycle of admoist was only 40 minute and there was always surpass time. Speed of tail out was changed from 16 rpm to 18 rpm which cause Inlet to outlet time at CRS dryer decrease from 690sec to 630sec.
Standard procedure for blend change was made as follow:

52
Fig 3.3.1: Admoist inter-operational time (Appendix-10)
Fig 3.3.2: CRS dryer inter-operational time (Appendix-10)

53
Inter operational time
 For admoist 480 seconds. Bin change time after operation is started is 120 seconds.
 For CRS dryer 7:30 minute. Bin change time after start of cutter is 180 seconds. (Inter-operational time for CRS dryer is taken after GFP is empty. As time required for tobacco to reach GFP from cutter at end of operation can vary from 40 sec to 240seconds)
 For CRS dryer intern-operational can be made to 6 minutes as without mixing two blend as dryer inlet to outlet time for inlet tobacco at start of operation is 6mins. Bin change time after start of cutter in this case is 330seconds.
f. Further scope
Standard tail out time of CRS dryer is 8 minutes but real tail out time observed was 10:30 minute. This time can be decrease by increase speed of air during tail-out or increase ahead start of tail out after 15seconds of tobacco inlet at end of operation, this time is 45 seconds now.

54
CHAPTER 4. CONCLUSION
During these Three month of OJT, I got an opportunity to learn about real industrial working experience and apply theoretical knowledge gained during my study to real- life problem at industries.
Project on research and data analysis made me familiar with basic of data collection along with way to find a pattern and data. Research on filling value provide opportunity to analysis complex process by breaking down into them into multiple individual steps. So that we can find out which single process is causing the problem.
Problem solving project made me familiar with common problem faced by company. These project help me to understand basic cause of any problem and to find it best solution out of lot of alternatives.
Optimization project made me familiar with bottleneck and cause of time lost during processes. And think creatively by breaking down complex process, so that each process can be optimized for overall increase in productivity.
During my project period through my and combine effort of PMD team, filling value of surya was increased by 3%, admoist protocol was passed, three design were presented to PMD team as solution of different problem, some process were redesign like CRS bin to CRS cutter belt speed and time, standard inter-operational time for CRS line was prepared.

55
REFERENCES
1. Wong, J.S and Wilson, T .L., 1976, "A Study of Variation in Tobacco Filling Power and Cigarette Firmness”. Amatil Report No. T-89.
2. Dr. M. Semfield, 1973, “Cigarette Manufacture Technology, Tobacco filling power: part 1”, Cigarettes Manufacturing Technology, 46.
3. S. M. Taylor, 1976, “Some Relations between Chemical and Physical Properties of Tobacco”, Imperial Tobacco R & D, 173rd symposium of the acs, 217-232.
4. B.M. Akehurts, 1968, “Tobacco”, 462.
5. Dr. M. Semfield, “Effects of making machine and process variables on filling power of tobacco Blends: part 1”, Tobacco Journal International, 354, 4/80
6. R.M. Gibb, 1962, “An investigation into differences in filling power bewtween factories”, Filling power of tobacco, reserch confernce.
7. P.M Pedersen , 1990,”A study of Tobacco filling power”, Filling power of tobacco, reserch confernce, 15.
8. Waldemar, Wochnowski F. K., 1989, “Mathematical Model to Optimize Cigarette Quality for Changes in Filling Power and the Control System on the Maker”, Korber AG
9. Dr. M. semfield, “The Relationship of the Physical Properties of the Cigarette to Blend Filling Power”, Tobacco Journal International, 509, 6/80.
10. Flesselles J., 1966, “Influence of the cut width of cut tobacco on certain physical characteristics of a cigarette” Ann. SEITA, DEE, sect.1, 4.,
11. Kamachi. T, Kawabata M., and Yoshitan, H., 1965, “Studies on bulkiness and filling capacity.” Sci.Pap.Cent.Res. Inst., 107
12. Pietrucci A., 1974), “Filling capacity of tobacco from an industrial point of view”, Ann. de Tabac, Paris SEITA, Sect I, ll,)

56
13. Wochnowski, 1988, “Cause of fluctuations in tobacco filling power and their influence in the quality of cigarettes”, Korber AG Hamburg, Coresta
14. De Grandpre Y. 1887, “A Review of Firmness and Tobacco Properties”, Imperial tobacco limited R & D
15. Philip Morris, August 1984, Aspects of tobacco processing.
16. Standard operating procedure of SNPL
17. www.tobaccodocuments.com 18. www.legacy.library.ucsf.edu
19 www.snpl.com

59
GLOSSARY
BALE: 1. A 50- to 75-pound case of unfermented tobacco,
EXTRUDED TOBACCO.
2. The rectangular packaging of leaf on the farm,
BURLEY farm bale.
3. A 1000-pound rectangular case of cellulose
acetate filter tow.
BRIGHT See FLUE-CURED TOBACCO. See also VIRGINIA
TOBACCO.
BULKING Storage of tobacco (leaf or steam or cut tobacco) in bin
for period of time. It helps in uniform distribution of moisture.
BURLEY An AIR-CURED tobacco. Burley tobacco is grown in
rich limestone soils. It is light brown to reddish brown in color
and has a somewhat greater FILLING POWER than
FLUE-CURED tobacco. Burley is light in body, with a
low sugar content and high alkaloid content. Burley
smoke is more basic (higher pH) than that of FLUECURED
CASE HARDENING Hardening and shrinking of particles caused by drying
from the surface faster than moisture migration from
the interior.
CASING Tobacco additives applied to improve moisture
retention and smoking ability; the process of applying
these additives to tobacco. A mixture of
HYGROSCOPIC AGENTS and/or plasticizing agents

60
and volatile or nonvolatile flavoring agents applied to
tobacco to condition it for processing (to reduce
breakage, facilitate cutting, etc.). Some commonly
known flavoring agents are: cocoa, chocolate,
ginger, cinnamon, vanilla, molasses, rum, brandy,
maple syrup, oils, honey, and sugar. See also: TOP FLAVORINGS.
CIGARETTE FIRMNESS A cigarette rods resistance to compression; the force
required to deform cigarettes a preselected amount;
the deformation of a cigarette after a predetermined
time at a given pressure; sometimes referred to as
CIGARETTE HARDNESS.
CURING The drying process for newly harvested tobacco. AIR
CURING is performed in widely ventilated barns under
natural atmospheric conditions (from which the name
comes) with little or no artificial heat; it takes 3-12
weeks. Light air-cured tobacco is very thin to medium
in body, light tan shaded toward red to reddish brown
in color, and mild in flavor. Burley is light air-cured.
Dark air-cured is medium to heavy in body, light to
medium brown in color. FLUE CURING is performed in
small, tightly constructed barns with artificial heat
beginning at 90 °F and ending round 170 °F; it takes
5-7 days. The name comes from the metal flues used

61
in the heating apparatus. Flue cured tobacco is yellow
to reddish-orange in color, thin to medium in body, and
mild in flavor. FIRE CURING is performed in ventilated
barns with open fires (from which the name comes)
allowing the smoke to come in contact with the
tobacco; it is alternated with air curing. Fire-cured
tobacco is light to dark brown in color, medium to
heavy in body, and strong in flavor. SUN CURING is
performed on racks in the sunshine (from which the
name comes) for set daily periods over 4 weeks,
depending on the weather. Sun-cured tobacco looks
similar to air-cured. Also: bulk curing, homogenized
leaf curing, cross-flow curing.
DENSIMETER Densimeter consist of graduated cylinder of radius(R)
with a closely fitting plunger and weight. The procedure
for measuring height is a known weight i.e. 20 ±0.05 gm.
weight is place in cylinder and plunger is inserted into
cylinder gradually weight of 3 kg is applied.
After 30 sec height (H) of plunger is measure from based of cylinder.
Volume occupied by sample= πR2H.
Filling value = volume* moisture correction factor.
DUST REMOVAL FILTER Separate tobacco dust from air. Dust are collected from
PMD and SMD using suction fan and send to DRF

62
ELASTICITY 1. The tendency for a cigarette to increase
ventilation rate at higher puffing pressure drop
2. The ability of a leaf to be stretched without
breaking. Leaf with elasticity has good drinking
quality and high FILLING POWER.
END STABILITY Also known as LOOSE SHORTS; Resistance
of a cigarette to lose tobacco. Determined
by quantitating the amount of tobacco which will fall
from the end of a cigarette during a standardized
agitation period reported as mg/cig fallout.
EXPANDED TOBACCO See EXPANSION
EXPANSION A chemical and/or physical procedure that increases
the volume of the cells of tobacco, thus increasing
shred dimensions and the FILLING POWER of the
shreds; performed on cured, cased or uncased filler.
Generally the tobacco is saturated with an inert gas in
a high-pressure vessel called an IMPREGNATOR.
Expansion of the tobacco then takes place in an
expansion tower through the introduction of high temperature
air. See also: PUFFED TOBACCO,
FILLING POWER The ability of tobacco to form a firm cigarette rod at a
given moisture content. A high filling power indicates
that a lower weight of tobacco is required to produce a

63
cigarette rod than is required with a tobacco of lower
filling power. CYLINDER VOLUME is used
interchangeably with filling power; a high cylinder
volume indicates a high filling power. Filling power is
mistakenly referred to as SPECIFIC VOLUME.
FIRMNESS A measure of the resistance of radial deformation of a
cigarette, expressed in counts. Ability of a cigarette to
resist compression.
FLUE-CURED TOBACCO Commonly called BRIGHT or VIRGINIA tobacco.
Flue-cured tobacco is lemon or orange yellow
in color. Flue-cured tobacco possesses a sweet
aroma and slightly acidic taste. It is high in sugar
content and low to average in nitrogenous materials,
acids and nicotine. It blends well with BURLEY and
MARYLAND tobaccos because its sugar content
smooth and neutralizes the smoke.
GRAVITY FEED PIPE GFP consists of a transparent tube with a set
of 3 photo sensors and maintain the level of
product within the GFP within reasonable limit
for continuity flow of product.
HUMECTANT Substance having an affinity for water, with stabilizing
action on the water content of a material; keeps within
a narrow range the moisture content caused by

64
humidity fluctuations; used in treating tobacco. See
also HYGROSCOPIC AGENT.
HUMIDITY CABINET Equipment use to maintain the set temperature
And humidity of sample kept inside it
HYGROSCOPIC AGENT HUMECTANT; ingredient added to tobacco to help it
retain moisture and plasticity. The first such agent was
glycerin, dating from the 1890’s.
MOISTURE CONTENT Percent of water content in total wet weight
of tobacco. Moisture Content is measured by
weighting 10±0.005 gram of sample in tin box
and then keeping tin box in oven for 3hours,
followed by half an hour in silica jell compartment.
Finally net weight of sample was taken.
Moisture content= 10- Net weight of tin after keeping in oven and silica jell.
PRESSURE DROP The change in pressure in a mass of flowing fluid as it
flows through a resisting element (such as a filter or
tobacco column). See RESISTANCE TO DRAW
PUFFED TOBACCO Expanded tobacco; tobacco whose particle size has
been increased by a combination of heat, high
pressure differential processing, and a puffing agent; a
means of expanding tobacco. See also EXPANSION.
QUALITY Of tobacco as a raw material, there are two

65
considerations: it must be pleasant to smoke and to
look at, and it must possess characteristics favoring
high manufacturing capacity. Tobacco quality is
composed of three major components:
1. PHYSICAL CRITERIA: stalk position, ripeness
and maturity, uniformity, foreign matter, strip yield
and size, filling power.
2. CHEMICAL CRITERIA: nicotine, sugar, petroleum
ether extracts, mineral components, alkalinity of
water-soluble ash, total nitrogen, protein nitrogen,
a-amino nitrogen, starch, nonvolatile acids, total
volatile bases.
3. SMOKE FLAVOR CRITERIA: strength, aroma,
mildness, and sharpness of smoking taste and
odor.
Also: Bruckner Quality Index, Pyriki Quality Index,
Shmuk Quality Index, Trifu Number.
RECONSTITUTED TOBACCO Tobacco dust, stems, by-products, etc. that are finely
ground, that may be mixed with a cohesive agent, and
that are rolled or cast into a flat sheet of uniform
thickness and quality. The sheet may be cut into any
size shreds.
TOP FLAVORINGS Volatile aromatic flavors applied to cut tobacco after

66
final drying, usually applied in the flavoring cylinder. See also CASING.
VIBRATING CONVEYER: Consists of a tray & a chassis which are connected to
Pair of fiber glass springs & a drive unit which causes the springs
To oscillate backward & forward, this produces
forward motion of the product at tray.
VIRGINIA TOBACCO A general reference to FLUE-CURED tobacco grown
anywhere in the world. BRIGHT tobacco.
SOURCES:
Dictionary of Tobacco Terminology, M. Z. DeBardeleben (1987) Philip Morris document ID:
2054432502/2628; Glossary/Acronyms List, C.S. Lincoln (1987); Brown & Williamson document, pages 620411092-620411135;
Proceedings of the Smoking Behavior – Marketing Conference 84709-840712 (1984), B&W document ID588065; RJR document ID 511331024-1028 dated 1993.

67
Appendix 1
Blend
SD of M.C After CRS Cutter
Average of M.C After CRS Cutter
BJ1/11
0.15
37.66
BJ1/13 0.55
36.60
BJF2/3
0.32
38.35
CT10/12
0.36
36.30
CT10/13
0.20
36.40
CT10/15
0.24
36.16
CT10/16
0.29
37.67
NG 5/27
0.34
38.48
NG5/19
0.49
36.82
NG5/21
0.34
36.65
NG5/22
0.25
36.26
NG5/23
0.32
37.16
NG5/25
0.44
37.88
NG5/27
0.23
37.44
NG5/29
0.32
36.10
NKT3/26
0.19
36.33
NKT3/27
0.39
36.24
NKT3/28
0.28
37.50
NKT3/29
0.46
38.79
NKT3/30
0.31
38.33
NKT3/37
0.31
38.26
NKT3/41
0.25
37.07
PLT6/15
0.14
38.07
PLT6/17
0.33
36.84
PLT6/22
0.26
36.56
PLT6/26
0.34
36.49
PLT6/30
0.21
37.11
PLT6/34
0.33
36.08
PLT6/35
0.21
36.98
PLT6/39
0.20
36.91
S.N
Blend
CV of Weighcon Weight
1
NKT106
0.38%
2
NG71
0.48%
3
NG72
0.41%
4
CT39
0.46%
5
NKT107
0.43%
6
CT40
0.41%
7
NKT108
0.44%
8
NKT109
0.40%
9
NG73
0.47%
10
NKT111
0.40%
11
NKT112
0.38%
12
NKT120
0.37%
13
NKT121
0.46%
14
NKT123
0.43%
15
NKT124
0.45%
16
NKT125
0.47%
17
NKT126
0.40%
18
BJ56
0.48%
19
NCD30
0.42%
20
NKT127
0.41%
21
NKT128
0.40%
22
NKT129
0.40%
23
BJ54 4.78%
24
NKT1/130
0.41%
25
BJO5/05
0.49%
26
BJO5/06
0.43%
27
NKT3/131
0.42%
28
NKT3/132
0.43%
29
BJ1/58
0.44%
30
BJ60
0.36%
Mean Moisture Content and SD of CRS Ex-cutter
CV of weighcon weight

68
Appendix 2
CRS
Operation number
Average M.C after H.C(approx.)
Ex- cutter
Ex- HT
Ex- Drier
Bin(initial)
Bin(final)
Bin(A. H.C)
Cutter to h.t
cutter to Bin
NG 5/36
14.00
40.59
50.82
45.67
25.22%
12.52%
NG 5/38
14.00
41.58
52.34
47.03
25.87%
13.09%
NG 5/39
14-15
41.68
49.87
47.85
19.64%
14.80%
NG 5/41
20.00
44.27
52.57
48.42
47.25
49.60
18.73%
12.03%
NG 5/43
16.00
46.40
56.86
50.18
50.43
22.54%
8.68%
NG 5/44
16.00
43.28
53.55
47.46
50.74
23.74%
17.24%
NG 5/45
15-16
44.86
55.96
50.43
51.46
52.30
24.74%
16.57%
NG 5/46
14.00
47.73
51.78
NG 5/48
14.00
42.44
51.63
45.30
45.78
47.63
21.64%
12.22%
NG 5/49
14-15
43.04
53.44
45.89
46.33
48.92
24.15%
13.66%
NG 5/51
15.00
43.07
52.99
49.66
48.71
49.10
23.03%
14.00%
NG 5/53
15.00
44.72
53.88
47.74
47.41
48.56
50.74
20.49%
13.46%
NG 5/55
14.00
42.48
50.28
47.52
47.77
48.49
18.35%
14.13%
NG 5/56
16.00
44.30
51.74
47.22
48.16
48.49
16.79%
9.44%
NG 5/57
16-17
45.47
56.37
50.24
50.73
54.42
23.98%
19.68%
NG 5/58
14-15
44.17
54.45
50.43
50.90
51.00
23.26%
15.47%
NG 5/59
49.05
NG 5/60
49.40
FV of CRS at different processing stages
 Filling value are always measured in mm3/gm
 Moisture content in %

69
Appendix 3
lamina
Operation Number
Average M.C after H.C(approx.)
Ex- cutter
Ex- HT
Ex- Drier
Ex- Drier(B.H. C)
flav
Cutter to h.t
Cutter to Dryer
NG 5/41
12.00
46.10
51.14
47.14
46.74
NG 5/43
12.00
45.98
53.50
50.73
16.36%
10.34%
NG 5/44
12.00
46.47
54.92
51.41
46.21
18.20%
10.63%
NG 5/45
12.00
47.33
54.11
51.77
48.37
14.34%
9.39%
NG 5/46
12.00
48.23
56.75
52.08
49.06
17.67%
7.97%
NG 5/48
12.00
48.26
53.69
50.34
46.33
47.64
11.25%
4.30%
NG 5/49
13.00
49.37
44.95
46.96
NG 5/51
13-12
48.82
52.99
51.17
46.74
46.69
8.55%
4.81%
NG 5/53
13-14- 12
46.06
53.17
51.20
47.24
49.77
15.43%
11.15%
NG 5/55
12.00
46.94
56.00
51.28
49.70
49.43
19.31%
9.24%
NG 5/56
14-13- f(10)
47.16
51.95
48.87
48.27
47.76
10.17%
3.63%
NG 5/57
14-13- 15
46.46
55.01
50.88
47.23
48.48
18.41%
9.50%
NG 5/59
13-12
48.97
55.43
53.00
48.96
50.71
13.20%
8.25%
NG 5/60
12.00
48.71
55.15
52.37
48.38
51.52
13.22%
7.52%
FV of CRS at different processing stages

70
Appendix 4
Before Calibration
After Calibration
Observation-1
Observation-2
Observation-3
Mean
0.1918
0.1995
0.1527
Standard Error
0.0077
0.0096
0.0036
Median
0.18
0.2
0.15
Mode
0.15
0.15
0.15
Standard Deviation
0.0542
0.0715
0.0244
Sample Variance
0.0029
0.0051
0.0006
Kurtosis
0.3507
-0.9841
0.6843
Skewness
0.9693
0.3286
1.1127
Range
0.21
0.25
0.1
Minimum
0.12
0.09
0.12
Maximum
0.33
0.34
0.22
Sum
9.4
10.97
6.87
Count
49
55
45
Largest(1)
0.33
0.34
0.22
Smallest(1)
0.12
0.09
0.12
Confidence Level (95.0%)
0.0156
0.0193
0.0073
Data summary of Wax thickness after and before Calibration

71
Appendix 5
Blend
Filling Value
Blend
Filling Value
Blend
Filling Value NG 5/78 49.55 NG 5/45 47.91
NG 5/11
46.01 NG 5/77 48.53 NG 5/44 49.99
NG 5/9
45.59 NG 5/76 47.98 NG 5/43 49.14
NG 5/8
46.37 NG 5/75 49.91
NG 5/42
45.89
NG 5/7
45.03 NG 5/72 48.53
NG 5/40
47.13
NG 5/6
48.05 NG 5/71 49.78
NG 5/39
48.26
NG 5/5
48.3 NG 5/70 49.25
NG 5/38
48.27
NG 5/4
48.16 NG 5/68 48.61
NG 5/37
48.26
NG 5/3
45.56 NG 5/66 50.43
NG 5/36
47.87
NG 5/2
49.03 NG 5/65 49.26
NG 5/33
47.36
NG 5/1
47.03 NG 5/64 47.86
NG 5/32
47.94
NG 5/63 48.31
NG 5/30
47.77
NG 5/62 50.31
NG 5/29
48.64
NG 5/61 49.57
NG 5/28
48.23
NG 5/60 49.5
NG 5/27
48.73
NG 5/59 49.67
NG 5/26
48.26
NG 5/58 50.15
NG 5/25
47.84
NG 5/57 51.47
NG 5/24
48.54
NG 5/56 48.67
NG 5/23
49.17
NG 5/55 49.27
NG 5/22
46.8
NG 5/54 46.45
NG 5/20
51.74
NG 5/53 48.18
NG 5/19
49
NG 5/52 49.26
NG 5/18
47.66
NG 5/51 49.39
NG 5/17
48.32
NG 5/50 49.7
NG 5/16
47.67
NG 5/49 49.68
NG 5/15
48.4
NG 5/48 49.32
NG 5/14
47.55
NG 5/47 49.33
NG 5/13
47.95
NG 5/46 48.18
NG 5/12
47.63
Filling Value of Surya from blend 1 to 78 (Source: QUAS Surya Nepal)

72
Appendix 6
Blend
M.C. inlet
M.C outlet
Steam Pressure H.T (bar)
set MC outlet
Dryer Inlet (bar)
Dryer Outlet (bar)
Cpk
Cp
Mean
S.D
Mean
S.D
Mean
S.D
Mean
S.D
Mean
S.D
Older Boiler
PLT75
39.3
0.3
15.4
0.3
4.1
0.6
15
5.5
0.7
3.8
0.1
0.7
1.1
BJ41
39.5
0.2
16.1
0.5
3.7
0.6
16
5.2
0.7
2.7
0.2
0.7
0.7
PLT78
39.0
0.4
15.6
0.3
4.4
0.2
16
6.0
0.2
4.8
0.7
0.6
1.0
PLT80
41.0
0.2
16.3
0.3
4.5
0.1
16
6.1
0.2
6.7
1.0
0.9
1.2
PLT81
40.0
0.2
16.3
0.3
4.1
0.3
16
5.5
0.4
6.5
0.5
0.9
1.3
New Boiler
PLT83
39.8
0.3
15.5
0.2
5.0
0.0
15.5
7.5
0.2
6.6
0.1
2.0
2.1
PLT85
38.7
0.3
15.6
0.1
5.0
0.0
15.5
5.6
0.4
6.6
0.5
2.9
3.2
PLT86
40.2
0.5
14.9
0.3
4.7
0.2
15
6.2
0.4
7.3
0.4
1.1
1.2
BJ43
40.9
0.3
15.9
0.3
5.0
0.0
16
5.8
0.6
6.7
0.5
1.1
1.2
PLT87
40.7
0.3
16.3
0.3
5.0
0.2
16
6.8
0.4
8.1
0.5
0.8
1.2
Different parameter during old and new boiler operation at CRS dryer

73
Appendix 7
Cover design for conveyer belt at CTS bin

74
Appendix 8
Pan design for sampling at HT

75
Appendix 9
Stand design for Serrico Trap

76
Appendix 10
Admoist in ( time in mins:sec)
hopper to inlet Admoist
inlet to outlet of Admoist
Ex- admoist to bin
Remark
2:00
2:50
30
Vibrating conveyer
12-15 sec
1:50
2:46
35
weighcon
45-55 sec
1:56
3:01
30
hopper to GFP
30-45 sec
1:45
2:51
30
1:55
2:45
35
1:55
2:55
35
2:00
2:50
35
1:50
2:50
35
Admoist out ( time in mins:sec)
hopper to inlet Admoist
inlet to outlet of Admoist
Ex- admoist to bin
1:40
8:50
30
1:40
8:40
35
1:56
8:46
35
1:36
8:30
30
1:50
8:30
35
1:30
8:45
35
1:35
8:40
35
1:40
8:40
35
CRS Out ( time in mins:sec)
Cutter to GFP
GFP to HT
HT to Ex-dryer
before
3:37
1:43
11:22
0:50
1:20
12:10
4:03
2:02
12:34
3:35
1:40
12:20
2:06
1:20
11:30
2:01
1:22
11:40
after
0:45
1:26
10:30
2:26
1:23
10:20
2:24
1:28
10:45
CRS In ( time in mins:sec)
Cutter to GFP
GFP to HT
HT to Ex- dryer
Before
0:51
1:07
7:00
0:45
1:05
6:20
0.47
1:20
6:45
0.46
1:10
6:40
0.46
1:08
6:10
0:45
1:00
6:30
0:52
0:58
6:16
1:00
1:07
6:20
After
1:00
0:55
6:00
13:12
13:55
6:05
Time at different point during process start and end at Admoist
Time at different point during process start and end at CRS Dryer

77
Appendix 11
Grant Chart of total OJT period
s

81

An OJT Report On 3 Month Internship at Surya Nepal

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Similar to An OJT Report On 3 Month Internship at Surya Nepal

Similar to An OJT Report On 3 Month Internship at Surya Nepal (20)

Recently uploaded

Recently uploaded (20)

An OJT Report On 3 Month Internship at Surya Nepal