Haycarb PLC is a leading manufacturer of activated carbon from coconut shells with over 35 years of experience. The document summarizes Lakshitha M.A.R's 3-month industrial training at Haycarb, including an introduction to the company's history and production process. As part of the training, Lakshitha conducted various projects in the maintenance department like preparing a new layout to improve efficiency, surveying dust plants to assess maintenance needs, creating an air flow meter to detect leaks, and standardizing roller parts to simplify inventory. The training provided hands-on experience in maintaining equipment and identifying solutions to issues.

1. INDUSTRIAL TRAINING AT
HAYCARB PLC-BADALGAMA.
04th January 2016 – 26th March 2016
Lakshitha M.A.R
EG/2012/1980
Department of Mechanical and Manufacturing Engineering
Faculty of Engineering
University of Ruhuna

2. Presentation Outline
 Introduction to Haycarb PLC
 Activated Carbon
 Manufacturing process
 Maintenance Department
 Training Experience
01

3. History
Hayleys PLC has initiated exporting coconut shell charcoal in
1970. Haycarb has been incorporated in 1973 which was rely
on its own leaders and employees as a subsidiary company
of Hayleys PLC.
Present status and main functions
Haycarb PLC is a world‘s leading manufacturing company of
coconut shell based activated carbon solutions with the
experiences of more than 35 years.
Introduction to Haycarb PLC
02

4. 03
Activated Carbon
What is Activated Carbon ?
Activated carbon is a carbonaceous, highly porous adsorptive
medium
Applications of activated carbon
 Drinking water treatment
 Industrial wastewater treatment
 Beverage industry
 Air Purification Applications
 Industrial air treatment
 Gold Extraction Applications
 Petroleum Sweetening
 Alcohol Purification
 Tea & Coffee Decaffeination etc.

5. 04
Manufacturing process
DQ Point
Pre activation
Pellet Plant Washing Plant
Activation
Post
activation
Packing

6. 05
Maintenance Department
o Keep the machineries in an acceptable condition for the
manufacturing process.
Maintenance Department
Electrical maintenanceMechanical maintenance
Preventive
maintenance
Predictive
maintenance
Corrective
maintenance
Shutdown
maintenance

7. 06
Training Experience
 Layout preparation
 Dust plant condition estimation survey
 Pitot tube U tube manometer preparation
 Standardization of trunion rollers and fittings

8. 07
Layout preparation
Problem
Lack of space to move among machineries in pellet making plant.
Solution
New layout of machineries were suggested
Benefit to the company
 Operator effort can be reduced.
 Pleasant working environment with more useful space.
 Maintenance easiness of the system.
 Simplicity of the system.
 Increased capacity of the production than before
 Easy handling of the equipment due to more space.

9. 08

10. 6:12 PM 09
Dust plant condition estimation survey
Problem
To identify the continuous pressure drop of the main pressure reservoir of the
firm
Solution
Remove all the diaphragms and springs of all the dust plants in the firm and
record
Benefit to the company
 A new numbering criteria was introduced for the dust plants
 Final report can be used as a reference to order spare parts for the dust
plants
 Provided an overall feedback about condition of the dust plants

11. 10

12. 11
Pitot tube U tube manometer preparation
Problem
Difficulty in identifying the leakages of compressed air
Solution
Prepare a U tube manometer as an air flow meter to attach to the main line
Benefit to the company
 Easiness to identify compressed air leaks.
 Reduce the leakages of compressed air
 Increase the life time of the compressors
 Reduce the maintenance labor hours
 Support to the continuous production

13. 12

14. 13
Standardization of trunion rollers and fittings
Problem
Difficulty in identifying the existing trunion roller types and their fittings and
handling of the inventory.
Solution
Standardize the trunion rollers and their fittings
Benefit to the company
 The maintenance process becomes easier
 The cost requirement for different types of rollers and fittings can be
reduced
 Inventory handling becomes easier
 The lifetime of the rollers and fittings can be increased due to equal force
distribution
 The noise and the heat generation also can be reduced

15. 14

16.  Maintenance procedure of the firm need to be updated
 Safety risk of the workers should be reduced
 The company need to have more skilled employees
Suggestions
15

17.  http://www.haycarb.com
 Industrial training report of Haycarb PLC
 Senior students presentations
References
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18. Thank you
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