Moserbaer India Ltd. operates a manufacturing plant in Greater Noida, UP that produces optical discs, solid state media, LEDs, photovoltaic cells, and modules. The plant has two main areas - MBIL for media production and PV for solar production. It generates most of its own power through diesel generators and purchases some from the government grid. The plant layout includes buildings for offices, cafeteria, security, and production areas. Key inputs and outputs were described for the diesel generators, injection molding machines, solid state media production, and solar cell and module manufacturing.

1. Moserbaer India Ltd. is based in New Delhi and is one of the top CD-R and DVD-R
manufacturing companies in the world. Conquering the world global market for Optical Discs, it
has now spread its research and production towards Solid State Media and LEDs. Being
currently on the down low as a result of the current global market, Moserbaer still keeps
venturing into promising businesses like SSM, Photovoltaic Cell and Module manufacturing and
Home Entertainment while still homing limited but equally promising Research and
Development.
A. MBIL Plant overview
The Moserbaer India Ltd. plant is situated in Phase III, Greater Noida, UP. It has two parts to it,
the MBIL (which constitutes of the Jewel Box Production, Optical Storage Media production and
Solid State Media production) and the PV (which constitutes of the Photovoltaic Cells and
Module production).
The Utility, in the MBIL side, is the main powerhouse of the factory and generates power partly
for MBIL and partly for PV. It consists of 5 Diesel generators (DG’s) which quench the need for
power for the factory. A considerable amount of power is also bought from the government
and is used for other minor purposes like lighting. The functions that need constant power
backup and the one’s that they cannot afford to stop are powered by the DG’s.
B. Plant layout
The Moserbaer factory situated in Greater Noida has the following layout:
The above is a loose (not to be scaled) representation of the various departments the factory
possesses. Buildings including the VIP Office, Satkar Cantene, Security, Jewel Box, SSM, PV and
Utility are labeled.
Layout of the Utility is shown below:
C. Input and Output
1. Input and output of the Diesel Generator:
The Diesel Generators, or DG’s, were the main power source for the Moserbaer factory
providing electricity to each and every piece of machinery operated in its various departments.
The DG’s are heavy generators which are operated using HFO (Heavy Fuel Oil or Heavy Furnace
Oil). HFO is a highly viscous residual fuel that is obtained in the last stages of the distillation of
Petroleum and then the refining of Crude Oil.

2. The schematic diagram below gives the flow of the HFO.
Figure 1 : HFO Process Flow
In the above diagram, arrowed lines indicate the flow of the fuel and circles resemble Pumps.
The HFO is bought in bulk at about Rs. 48/L and are transferred to store in the storage tanks.
There are three storage tanks which have a capacity of 700 kL each. From the storage tanks, the
HFO is then transferred via the Transfer Pump to a systemof two vessels known as the HFO
separator. These two tanks are connected to each other allowing forward and reverse flow. The
second vessel is kept at a height to support the reverse flow of the fuel. The two vessels have
an interconnected systemwhich makes the first vessel flow excess fuel into the second and
helps the second expel excess fuel back into the first.
After passing the HFO Separator, the fuel goes through the Feeder System, into the Booster and
then into the DG. And the DG itself consists of a generator and an alternator.

3. 2. Input and Output of the Injection Molding Machine (JB)
The Moser Baer factory uses the J-AD series J 280 580H Open Nozzle type Injection Molding
machines with High Melter M7 Screws and a total weight of around 13.6 tons. A basic
schematic diagram for the machine is as below:
The hopper is the vessel in which the raw PP (Polypropene) or GPPS (General Purpose
Polystyrene) is kept ready to go through the Screw Barrel where it is melted at gradually
increasing temperatures. When the molten plastic reaches the mold it fills it. The mold also
contains its own set of thermocouples to keep the plastic heated at an ideal temperature to
keep it from completely solidifying while also keeping it from its molten state to avoid defects.
3. Input and Output of the SSM IC Machine
The SSM (Solid State Media) is the department in the Moser Baer factory that is pertaining to
the production of flash drives of varying capacities and for various companies.
Circuit Boards are imported by Moser Baer to start the production process. The various
components (Resistors, capacitors, LEDs etc.) are then glued to the circuit board according to
the directions and specifications of the circuit board.
It IC then is attached to the USB 2.0 connector which enables it to be read by USB readers.
These then undergo a process in which the NAND memory is attached to the circuit board. Then
the flash drive goes for testing before it’s cased.
After that the flash drive undergoes NAND activation and F1/F2/H1/H2 testing. Any flash drives
showing defects after the NAND activation and F2 testing are sent for troubleshooting.

4. A. PV Plant Overview
The Photovoltaic plant is where Moser Baer manufactures PV modules right from the making of
mere wafers and where the research and development for PV Modules and Solar Cells takes
place. The modules are manufactured using space where the Thin Film manufacturing used to
happen.
B. Input and Output
The process of making PV Modules starts from making Silicon Wafers by starting off with a P
Type and then adding an N substrate to it. These are called P Type Solar Cells.
After the addition of the N type, the metallic strips and bus bars are added on top of the N type
submerging to reach the P-N Junction to collect electrons.
Then the solar cells are connected together in series to make solar modules, which are then
coated with an Antireflective coating (to reduce reflection of photons by the module) and then
covered with a glass protective layer.
Conclusion
In the two weeks spent in Moserbaer India Ltd. Factory in GN, many processes and machines
were a key part of the trainee program. The various plants including the Utility (the main
powerhouse of the factory and also a supply of compressed air), the Jewel Box (production of
Jewel Box, Slim Case and Cake Box) and the SSM (production of Solid State media, namely flash
drives) were studied in an elementary level.