Technical Aspects of Liquid Filling and Powder Filling Lines of Small Packing Plant, Crop...

8/14/2019 Technical Aspects of Liquid Filling and Powder Filling Lines of Small Packing Plant, Crop Division.pdf

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A Report On

Technical Aspects of LFM & PFM ofSmall Packing Plant, Crop Division

By

Swastik Mohapatra

2007B5A8567G

Under the guidance of

Mr. H. K. Bhatt


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ABSTRACT

The topic of my project is Technical Aspects of LFM and PFM of Small PackingPlant, Crop Division . The Crop Division, earlier known as the Agrochemicals

Division was established in the year 1967. The small packing plant is an integral part of

the division as it deals with packing and despatch of the various products produced by

the crop division. This unit of the division is crucial for the division because it improves

the marketability of its products.

The aim of my project is to study the various machines used in the packing processes in

the small packing plant, the level of automation in the various lines, their technical

details and do a technical comparison analysis between machines of various

manufacturers.

The current process of herbicide packing in line-1 and line-2 and the powder filling

machine are semi automatic at best. For packing of a single product there is a huge

amount of manpower involved. For instance in herbicide packing for packing of a

single product named Revo about 28 people were involved in packing and inspection at

full speed. Thus the aim here is to induct suitable machines into the line thus reducing

the manpower involved, improving packing speed, reducing errors and spillage thus

saving time and capital.


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ACKNOWLEDGEMENT

An activity can be termed as an accomplishment only when the purpose is

fulfilled. The accomplishment of any activity involves a continuous, unflinching effort,

motivation and support from its mentor. I would like to thank my mentor and guide for

this project, Mr. Haresh K Bhatt , Senior Manager (Instrumentation), TE Unit, Colors

Division for his constant support and guidance, without which my report would have

never been complete. I would also like to forward my heartfelt thanks to Mr. Nilesh

Doshi (Instrumentation), Crop Division whose eager help was instrumental in shapingup of my report. I would like to offer my regards to Mrs. Poorva Shah (H.R

Department) who helped us a lot in getting various facilities like accommodation,

fooding and internet facility at the office which were instrumental for us in the entire

learning process here. I would also offer my sincerest regards to my PS-2 instructor Mr.

Shashank Belsare who has always been very helpful and considerate to us in the

smooth conduct of the PS.

I would also like to offer my sincere gratitude to my fellow BITSian PS-2 mates who

were always very helpful mentally.

I would also like to thank the authors of all the books and the websites which provided

me with most of the data used by me in this project.

Last but not the least I would like to thank the God for showing me the right way

throughout the project without whom this report would have never been.

Swastik Mohapatra2007B5A8567G


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Table of Contents

Topic Page

1. Cover Page 1

2. Title Page 2

3. Abstract 3

4. Acknowledgement 4

5. Introduction 6

6. Liquid Filling Line 7

7. Powder Filling Machine 15

8. Conclusion 17

9. Bibliography 18


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INTRODUCTION

Atul Ltd. is the flagship brand of Lalbhai Group , one of the oldest business houses of

India, with interests mainly in textiles and chemicals. Incorporated in 1947, Atul Ltd

(formerly Atul Products Ltd) was founded by Kasturbhai Lalbhai with a dream to

make India self reliant in chemicals, generate employment on a large-scale and create

wealth for the society. Thus with such early beginnings Atul became the first private

sector company in India to be inaugurated by Pt. Jawaharlal Nehru.

Atul Ltd. has two plants: located at Ankleshwar in Gujarat and Atul, near Valsad in

Gujarat. It has primarily six divisions namely Crop Division, Colors Division,

Aromatics, Bulk Chemicals & Intermediates, Pharmaceutical & Intermediates and

Polymers.

Atul is situated on the banks of the river Par in the Valsad district of Gujarat state, 200

km north of India's commercial capital, Mumbai. When it was established in 1947, the

village was classified as a backward village. But the peripheral development schemes

undertaken by Atul have transformed this place into a model village. A sprawlingcampus of 1250 acres is today lush green and eco-friendly, so much so that even the

WWF has set up a division at Atul in 1987.

The excellent infrastructure includes 1000 houses with garden, choice of English

medium schools, good medical services and recreational facilities such as Badminton,

Billiards, Sauna, Squash, Swimming Pool, Table Tennis, Tennis etc, of international

standards. The Complex is self-sufficient in water and electricity and hascommunication networks, presence of four banks and ATMs.


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LIQUID FILLING LINE

In the small packing plant, Crop Division, there are multiple liquid filling lines which

pack and despatch a wide variety of products like insecticides, pesticides and

herbicides. An ideal Automatic Liquid Filling Line comprises of 9 components. Many

of these components are either not present or are in very poor working condition at the

small packing plant. As a result a lot of manpower is involved, frequent losses occur

due to spillage and inaccurate quantity of packing and overall loss of time takes place.


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A standard liquid filling line comprises of the following components:

1) Turn Table

2) Automatic 4 head / 6 head volumetric liquid filling machine.

3) Automatic single / multiple head screw capping machine.

4) Induction cap sealing system.

5) Automatic self adhesive vertical labelling machine.

6) Automatic shrink tunnel.

7) Packing line conveyor belt.

8) Semi Automatic Box Strapping Machine

1) Turn Table


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Turntable is used for automatic loading of bottles onto the packing conveyor belt line.

Machine Dimensions & Technical Specifications:

These were the proposed dimensions and technical specifications of one of themanufacturers of turntable.

Machine dimensions: 925 mm X 925 mm X 1160 mm. Adjustable height of the disk: 860 mm to 910 mm. Container size (Round Shape): Diameter 22 mm to 100 mm. Power characteristics: 0.5HP/ 220V/50Hz.

Diameter: 36 Powered by ACVFD (AC Variable Frequency Drive). 3 step pulley for variable speed of bottle loading onto the conveyor line.

2) Automatic volumetric liquid filling machine


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These were the proposed dimensions and technical specifications of one of the

manufacturers of the single head screw capping machine.

No. of heads: 1 Height of conveyor: 860 mm to 910 mm (adjustable). Screw cap diameter: 22 mm to 56 mm. Height of screw cap: 15 to 35 mm. No cap, machine stop arrangement. No bottle, no capping system. Container size:

Round shape: Diameter 22 mm to 56 mm, Height: 100 mm to 650 mm.

Flat/Square shape: Diameter No container no cap arrangement.

4) Induction Cap Sealing System


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6) Automatic Shrink Tunnel, FLP Motor and

Electrical with Conveyor

Heater capacity: 8 kW

Max number of bottles per hour: 4800 Container diameter: 25 mm to 110 mm Width of conveyor: 90 mm

7) Semi Automatic Box Strapping Machine


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Tension strength: 15 kgf to 50 kgf. Strapping speed: 2 sec / strap. Strap width 6, 9, 12, 15.5 (mm) (adjustable).


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POWDER FILLING MACHINE

Form Fill Seal (Auger Filler) Machine:


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Filling weights: 500 g to 5 kg. Pouch type: Pillow cover type (centre seal and fin seal on opposite sides). Packaging material: All heat sealable laminates.

Speed: 30-40 pouches per minute (500 g), 10 pouches per minute (5 kg). Pouch Sizes: 500 g: 235 mm x 189 mm (Ht)

5 kg: 490 mm x 385 mm (Ht) Accuracy: SD 2 %.


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CONCLUSION

The Indian chemicals industry is the twelfth-largest industry in the world and the thirdlargest in Asia in terms of volume. The Indian chemicals industry is currently valued at

around US$ 35 billion. India has a diversified manufacturing base with a capacity to

produce quality chemicals for world consumers. Atul Ltd. is one of the pioneers of the

Indian Chemicals Manufacturing industry. In a large integrated chemical plant such as

Atul Ltd a large number of processes take place simultaneously in a coordinated manner

to give the final product. In this project II have tried to throw some light on the

Automatic Liquid Filling line and Form Fill Seal machine (Powder Packing) used/

proposed to be used in Small Packing (Crop Division). Various technical details and

specifications have been covered in the report. This has been a wonderful experience to

learn by seeing real automated/semi-automated packing lines in an industrial

environment.


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BIBLIOGRAPHY

1) Quotations of Liquid filling lines and Auger Filler machines from GMP,

Wraptech, Pakona, Swanpack and National Pharma.

2) Manuals from crop division office and engineering office.

Technical Aspects of Liquid Filling and Powder Filling Lines of Small Packing Plant, Crop...

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